.
This work is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License. Attribution: Jean Vieille
Work: ISA8895 Implementation Section: Function Chapter: Physical Process Management
Language: English Version: V3 - 05/2011
Jean Vieille
www.syntropicfactory.info j.vieille@syntropicfactory.info
Research community www.controlchainmanagement.org Consulting group www.controlchaingroup.com
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
2
CC functional domains
3_30_ISA8895_Function_PhysicalProcessManagement
Product Asset Management Inventory Asset Management Physical Asset Management Human Asset Management
TOGAF ITIL ISA88 + ISA95
ISA88 ISA95
3
IT Asset Management
Information Elements
Cliquez pour ajouter Stdtableau un Domain sur l'icôneModel Information elements Product Asset Inventory Asset Physical Asset Human Asset Equipment Control Physical Process Control Physical Process Mngt Operation Process Mngt Product Product Material Physical Equipment Personnel Procedural Procedural Segment Operation Activity ISA88 ISA95 ISA95 ISA88 ISA95 ISA95 ISA88 ISA88 ISA95 ISA95 Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Operation Processes Activities / Tasks 4
3_30_ISA8895_Function_PhysicalProcessManagement
Who's / What's concerned?
PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau Typ.IT app
Customer order processing Production planning & scheduling Production control Material and energy control Procurement Quality assurance Product inventory control Product cost accounting Product shipping administration Maintenance management Research & development Engineering
X R
X
X
X
X 3_30_ISA8895_Function_PhysicalProcessManagement
5
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
6
ISA95 Segments
A segment describes a product related processing stage involved in Ø Specification for the product definition Ø Description of the capability of the facility Ø Requirement for executing a specific production Request In ISA-95, it currently Ø Identifies the processing stage (its identifier) Ø describes the resources involved for its execution Segment are logical views of the actual processing Ø They can be defined hierarchically. A segment can § Correspond to the product itself (possibly involving the whole plant or even several plants) § Correspond to a single ISA88 phase
3_30_ISA8895_Function_PhysicalProcessManagement 7
ISA95 Segments
The picture below represents the process segment information
Assembly
Inspect
Paint
I-Beam Laborer 3x 8 hour Inspector 2x .25 Hour Mixing Cans Rollers Certified Painter = TRUE
Type = Stainless Steel
3_30_ISA8895_Function_PhysicalProcessManagement
8
ISA95 Segments
A logical Telescopic View of the Production System
Drug XX manufacturing
Raw Materials
S1. Active Ingredient
S2 Shaping
S3 Packing
Finished Products
S1.1 Ingredient 1 Manufacturing
S1.2 Ingredient 2 Manufacturing
S1.3 Blending
S1.1.1 Pre-mixing
S1.1.2 Reaction
S1.1.3 Filtration 9
3_30_ISA8895_Function_PhysicalProcessManagement
Use of Segments for planning purpose
Collection of Process Segments B C A
Parameters Equipment Material Personnel
Product Segments for a single product definition, with routing (e.g. Product YYY)
must reference
E D
C
E
A
must reference C
Segment Requirements for a specific production request (e.g. Lot 123 of Product YYY E A
Product Parameters Equipment Specifications Material Specifications Personnel Specifications
Production Parameters Equipment Requirement Material Requirement Personnel Requirement
3_30_ISA8895_Function_PhysicalProcessManagement
10
ISA95 Process Segment Model
0..n has an execution dependency on
Process Segment
is a collection of
0..n
0..n May be made up of
Process Segment Dependency
0..n
0..n
0..n
0..n
0..n
Process Segment Parameter
0..n May be made up of
Personnel Segment Specification
Has properties of 0..n
Equipment Segment Specification
Has properties of 0..n
Physical Asset Segment Specification
Has properties of 0..n
Material Segment Specification
Has properties of 0..n
0..n Is assembled from
Personnel Segment Specification Property
0..n Corresponds to element in 1..1
Equipment Segment Specification Property
0..n Corresponds to element in 1..1
Physical Asset Segment Specification Property
0..n Corresponds to element in 1..1
Material Segment Specification Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
Resources
3_30_ISA8895_Function_PhysicalProcessManagement
11
From ISA88 Process Model to ISA95 ProductDefinition
ISA95 defines Segment as the breakdown of Operation physical activities Ø Product Segment Ø Process Segment Ø Operation/Work Segment (futur) The ISA-95 Segment model can address all stages of Product Lifecyle Ø Equipment independent processing requirement (the current topic) Ø Process operation description Ø Facilitiy's processing capabilities It can implement ISA88 Process Elements defined in Product hierarchy model and described in EIR model
3_30_ISA8895_Function_PhysicalProcessManagement
12
Operations Definition Model
Has a reference to < Has a reference to >
Bill of Resources (External)
Has associated > May be made up of 0..n has an execution dependency on 0..n 0..n
Operations Definition
Has associated 0..n 1..n 1..1
Work Definition (External)
Bill of Material (External)
may have a reference to >
Has associated > 0..n
May have a reference to > Corresponds to 0..n 1..n
Operations Material Bill
0..n
Operations Segment
Process Segment
Operations Segment Dependency
0..n 0..n
Is a collection of
1..1
Operations Material Bill Item
0..n
0..n Is assembled from
0..n
0..n
0..n
1..n
Parameter Specification
0..n May be made up of
Personnel Specification
Equipment Specification
Physical Asset Specification
Material Specification
0..n Is assembled from
0..n
0..n
0..n
0..n
Personnel Specification Property
0..n Corresponds to element in
Equipment Specification Property
0..n Corresponds to element in
Physical Asset Specification Property
0..n Corresponds to element in
Material Specification Property
0..n Corresponds to element in
1..1
1..1
1..1
1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
Resources 13
3_30_ISA8895_Function_PhysicalProcessManagement
Process and Product Segments
Process segment: manufacturing capability Ø Defines the manufacturing process available per segment Ø Gather the required resources to execute the defined production segments Product Segment: manufacturing requirements Ø Defines the product specifications per production segment Ø Details the required resources for this production segment § Personnel (ex:3 operators) § Equipment (ex:1 packing machine) § Materials (ex: 1500 bottles) § Parameters (ex: shape, size) May correspond to ISA88.01 definitions: (exemples) Ø Product segment --> Process stage (General/Site recipe) Ø Process Segment --> Unit Procedure (Master Recipe)
3_30_ISA8895_Function_PhysicalProcessManagement 14
Product Segment vs Process Segment
Ø
More information at the Product Segment level = § (-) less information at the Process segment level, § (+) more flexibility (+) More exchanged information
Process Segments: · Pen Assembly · Ball · Reservoir · Point · Ink · Body Process Segments : · Make balls · ...
·
Product segment · CrystalBlackFineBall
Product segment: · CrystalBlackFineBall · Ball · Reservoir · Point · Ink · Body · Assembling
Business Manufacturing
Pen Assembly
3_30_ISA8895_Function_PhysicalProcessManagement
15
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
16
Enterprise global model
Shareholders Bank Gover Money In nment etc Capital Benefit Money Out Emplo yees, Gover nment, Bank, etc
Company Investment, Inventory & Cash Flow Profit
Business Money In Customers Knowledge In Money Chain Control Design Knowledge Out Chain Energy Chain Energy R. Material Suppliers Money Out
F. Product
3_30_ISA8895_Function_PhysicalProcessManagement
17
Segment as a Process
The Segment concept in ISA95 is one of the most poweful feature in ISA95. Pragmatically defined as a grouping of resources, it in fact model the physical processes. As any process, they can be characterized by: Owner I/Os Metrics Best Practices Resources Workflow involving Activities, roles, resources...
puts
Segment Outputs
Best Practices
Metrics Resources
3_30_ISA8895_Function_PhysicalProcessManagement
18
Energy Chain = Segments
Company Money Enterprise Money Money Chain Information Supplier Energy Chain = Segments Customer Material Energy Personnel Equipment IT Asset Money Information Money
Material Energy Personnel Equipment IT Asset Money Information
Trash, Scrap Losses
3_30_ISA8895_Function_PhysicalProcessManagement
19
A Segment is a Transformer
Segment Resource Flow Usage Taken From More specifically, a Stored segment is a Converted "Transformer" that acts on Invested a target `flowing" resource Borrowed that increases its value Tested through the segment, Processed thanks to used resources Consumed that elevate the value to Produced Exploited the target resource at Served some cost. Recovered Sent To Resources are Equipment, Material and Personnel in ISA95, but they can be expanded to other types. 20
rce Flow
Resource Money Material Person Equipment IS IT Asset Information Energy
3_30_ISA8895_Function_PhysicalProcessManagement
Process Segment ISA95 + EPE ISA88
Fabrication support Traitement De surface
Bobinage
Segments Personnel Equipment Material Process Parameters (e.g. Grammage)
Cellule Process
Procédure Procédure d'Unité Opération
material
Unité Module Équipement Module de Contrôle Phase
Personnel
3_30_ISA8895_Function_PhysicalProcessManagement
Equipment
ISA88 defines Equipment and Recipe Procedural Elements that are related to Equipment entities. EPE and RPE are inherited by the segment through the Equipment entities it encompasses. They constitute the behavioural aspects of the segment 21
Operation segment
Location
1...1 0...n
Operation Segment
0...n Corresponds to
0...n
Process Element
0...n
0...n
0..n 0..n 0..n Is build on 0...n Is based on
0..n
IT Asset 0..n
0..n
Is fulfilled by
EPE 0..n 0..n Service Activates
0...n 0...n
RPE SOP
MRTC
0...n
Data Parameter
Data Parameter
3_30_ISA8895_Function_PhysicalProcessManagement
22
Correspond to
0...1 Taken From Personnel Consumed Equipment Produced Resource Material Tested IT Asset Sent To ... ... From Equipment
Is implemented by
0...n
0..n
KPI
Data Parameter
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
23
Exercise 1
Identify a set of segments classes of a facility of your choice Associate Personnel Classes, Equipment Classes and Material Classes to these segments Create instances of these segments for a given facility
3_30_ISA8895_Function_PhysicalProcessManagement
24
Work: ISA8895 Implementation Section: Function Chapter: Physical Process Management
Language: English Version: V3 - 05/2011
Jean Vieille
www.syntropicfactory.info j.vieille@syntropicfactory.info
Research community www.controlchainmanagement.org Consulting group www.controlchaingroup.com
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
2
CC functional domains
3_30_ISA8895_Function_PhysicalProcessManagement
Product Asset Management Inventory Asset Management Physical Asset Management Human Asset Management
TOGAF ITIL ISA88 + ISA95
ISA88 ISA95
3
IT Asset Management
Information Elements
Cliquez pour ajouter Stdtableau un Domain sur l'icôneModel Information elements Product Asset Inventory Asset Physical Asset Human Asset Equipment Control Physical Process Control Physical Process Mngt Operation Process Mngt Product Product Material Physical Equipment Personnel Procedural Procedural Segment Operation Activity ISA88 ISA95 ISA95 ISA88 ISA95 ISA95 ISA88 ISA88 ISA95 ISA95 Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Operation Processes Activities / Tasks 4
3_30_ISA8895_Function_PhysicalProcessManagement
Who's / What's concerned?
PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau Typ.IT app
Customer order processing Production planning & scheduling Production control Material and energy control Procurement Quality assurance Product inventory control Product cost accounting Product shipping administration Maintenance management Research & development Engineering
X R
X
X
X
X 3_30_ISA8895_Function_PhysicalProcessManagement
5
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
6
ISA95 Segments
A segment describes a product related processing stage involved in Ø Specification for the product definition Ø Description of the capability of the facility Ø Requirement for executing a specific production Request In ISA-95, it currently Ø Identifies the processing stage (its identifier) Ø describes the resources involved for its execution Segment are logical views of the actual processing Ø They can be defined hierarchically. A segment can § Correspond to the product itself (possibly involving the whole plant or even several plants) § Correspond to a single ISA88 phase
3_30_ISA8895_Function_PhysicalProcessManagement 7
ISA95 Segments
The picture below represents the process segment information
Assembly
Inspect
Paint
I-Beam Laborer 3x 8 hour Inspector 2x .25 Hour Mixing Cans Rollers Certified Painter = TRUE
Type = Stainless Steel
3_30_ISA8895_Function_PhysicalProcessManagement
8
ISA95 Segments
A logical Telescopic View of the Production System
Drug XX manufacturing
Raw Materials
S1. Active Ingredient
S2 Shaping
S3 Packing
Finished Products
S1.1 Ingredient 1 Manufacturing
S1.2 Ingredient 2 Manufacturing
S1.3 Blending
S1.1.1 Pre-mixing
S1.1.2 Reaction
S1.1.3 Filtration 9
3_30_ISA8895_Function_PhysicalProcessManagement
Use of Segments for planning purpose
Collection of Process Segments B C A
Parameters Equipment Material Personnel
Product Segments for a single product definition, with routing (e.g. Product YYY)
must reference
E D
C
E
A
must reference C
Segment Requirements for a specific production request (e.g. Lot 123 of Product YYY E A
Product Parameters Equipment Specifications Material Specifications Personnel Specifications
Production Parameters Equipment Requirement Material Requirement Personnel Requirement
3_30_ISA8895_Function_PhysicalProcessManagement
10
ISA95 Process Segment Model
0..n has an execution dependency on
Process Segment
is a collection of
0..n
0..n May be made up of
Process Segment Dependency
0..n
0..n
0..n
0..n
0..n
Process Segment Parameter
0..n May be made up of
Personnel Segment Specification
Has properties of 0..n
Equipment Segment Specification
Has properties of 0..n
Physical Asset Segment Specification
Has properties of 0..n
Material Segment Specification
Has properties of 0..n
0..n Is assembled from
Personnel Segment Specification Property
0..n Corresponds to element in 1..1
Equipment Segment Specification Property
0..n Corresponds to element in 1..1
Physical Asset Segment Specification Property
0..n Corresponds to element in 1..1
Material Segment Specification Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
Resources
3_30_ISA8895_Function_PhysicalProcessManagement
11
From ISA88 Process Model to ISA95 ProductDefinition
ISA95 defines Segment as the breakdown of Operation physical activities Ø Product Segment Ø Process Segment Ø Operation/Work Segment (futur) The ISA-95 Segment model can address all stages of Product Lifecyle Ø Equipment independent processing requirement (the current topic) Ø Process operation description Ø Facilitiy's processing capabilities It can implement ISA88 Process Elements defined in Product hierarchy model and described in EIR model
3_30_ISA8895_Function_PhysicalProcessManagement
12
Operations Definition Model
Has a reference to < Has a reference to >
Bill of Resources (External)
Has associated > May be made up of 0..n has an execution dependency on 0..n 0..n
Operations Definition
Has associated 0..n 1..n 1..1
Work Definition (External)
Bill of Material (External)
may have a reference to >
Has associated > 0..n
May have a reference to > Corresponds to 0..n 1..n
Operations Material Bill
0..n
Operations Segment
Process Segment
Operations Segment Dependency
0..n 0..n
Is a collection of
1..1
Operations Material Bill Item
0..n
0..n Is assembled from
0..n
0..n
0..n
1..n
Parameter Specification
0..n May be made up of
Personnel Specification
Equipment Specification
Physical Asset Specification
Material Specification
0..n Is assembled from
0..n
0..n
0..n
0..n
Personnel Specification Property
0..n Corresponds to element in
Equipment Specification Property
0..n Corresponds to element in
Physical Asset Specification Property
0..n Corresponds to element in
Material Specification Property
0..n Corresponds to element in
1..1
1..1
1..1
1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
Resources 13
3_30_ISA8895_Function_PhysicalProcessManagement
Process and Product Segments
Process segment: manufacturing capability Ø Defines the manufacturing process available per segment Ø Gather the required resources to execute the defined production segments Product Segment: manufacturing requirements Ø Defines the product specifications per production segment Ø Details the required resources for this production segment § Personnel (ex:3 operators) § Equipment (ex:1 packing machine) § Materials (ex: 1500 bottles) § Parameters (ex: shape, size) May correspond to ISA88.01 definitions: (exemples) Ø Product segment --> Process stage (General/Site recipe) Ø Process Segment --> Unit Procedure (Master Recipe)
3_30_ISA8895_Function_PhysicalProcessManagement 14
Product Segment vs Process Segment
Ø
More information at the Product Segment level = § (-) less information at the Process segment level, § (+) more flexibility (+) More exchanged information
Process Segments: · Pen Assembly · Ball · Reservoir · Point · Ink · Body Process Segments : · Make balls · ...
·
Product segment · CrystalBlackFineBall
Product segment: · CrystalBlackFineBall · Ball · Reservoir · Point · Ink · Body · Assembling
Business Manufacturing
Pen Assembly
3_30_ISA8895_Function_PhysicalProcessManagement
15
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
16
Enterprise global model
Shareholders Bank Gover Money In nment etc Capital Benefit Money Out Emplo yees, Gover nment, Bank, etc
Company Investment, Inventory & Cash Flow Profit
Business Money In Customers Knowledge In Money Chain Control Design Knowledge Out Chain Energy Chain Energy R. Material Suppliers Money Out
F. Product
3_30_ISA8895_Function_PhysicalProcessManagement
17
Segment as a Process
The Segment concept in ISA95 is one of the most poweful feature in ISA95. Pragmatically defined as a grouping of resources, it in fact model the physical processes. As any process, they can be characterized by: Owner I/Os Metrics Best Practices Resources Workflow involving Activities, roles, resources...
puts
Segment Outputs
Best Practices
Metrics Resources
3_30_ISA8895_Function_PhysicalProcessManagement
18
Energy Chain = Segments
Company Money Enterprise Money Money Chain Information Supplier Energy Chain = Segments Customer Material Energy Personnel Equipment IT Asset Money Information Money
Material Energy Personnel Equipment IT Asset Money Information
Trash, Scrap Losses
3_30_ISA8895_Function_PhysicalProcessManagement
19
A Segment is a Transformer
Segment Resource Flow Usage Taken From More specifically, a Stored segment is a Converted "Transformer" that acts on Invested a target `flowing" resource Borrowed that increases its value Tested through the segment, Processed thanks to used resources Consumed that elevate the value to Produced Exploited the target resource at Served some cost. Recovered Sent To Resources are Equipment, Material and Personnel in ISA95, but they can be expanded to other types. 20
rce Flow
Resource Money Material Person Equipment IS IT Asset Information Energy
3_30_ISA8895_Function_PhysicalProcessManagement
Process Segment ISA95 + EPE ISA88
Fabrication support Traitement De surface
Bobinage
Segments Personnel Equipment Material Process Parameters (e.g. Grammage)
Cellule Process
Procédure Procédure d'Unité Opération
material
Unité Module Équipement Module de Contrôle Phase
Personnel
3_30_ISA8895_Function_PhysicalProcessManagement
Equipment
ISA88 defines Equipment and Recipe Procedural Elements that are related to Equipment entities. EPE and RPE are inherited by the segment through the Equipment entities it encompasses. They constitute the behavioural aspects of the segment 21
Operation segment
Location
1...1 0...n
Operation Segment
0...n Corresponds to
0...n
Process Element
0...n
0...n
0..n 0..n 0..n Is build on 0...n Is based on
0..n
IT Asset 0..n
0..n
Is fulfilled by
EPE 0..n 0..n Service Activates
0...n 0...n
RPE SOP
MRTC
0...n
Data Parameter
Data Parameter
3_30_ISA8895_Function_PhysicalProcessManagement
22
Correspond to
0...1 Taken From Personnel Consumed Equipment Produced Resource Material Tested IT Asset Sent To ... ... From Equipment
Is implemented by
0...n
0..n
KPI
Data Parameter
Agenda
Introduction Segment (ISA95 Resource View) Segment (Extended) Exercise
3_30_ISA8895_Function_PhysicalProcessManagement
23
Exercise 1
Identify a set of segments classes of a facility of your choice Associate Personnel Classes, Equipment Classes and Material Classes to these segments Create instances of these segments for a given facility
3_30_ISA8895_Function_PhysicalProcessManagement
24
Johann Sebastian Bach. the music closest to silence, closest, in spite of its being so highly organized, to pure, one-hundred-degree proof Spirit" (Aldous Huxley, Island)