Practical Enterprise Modelling: ISA 88 and ISA 95 standards

IEC SB3 Sponsored Seminar Workshop on Industrial Automation Objects 3-4 April 2001, Geneva, Switzerland
Jean Vieille, Consultant ISA SP88 & SP95 committees member [email protected]

Agenda
ISA 88 and 95 in SCM and Production Scheduling ISA 95 : Enterprise-Production Communication ISA 88 : Modular Control

ISA 88 and 95 in SCM and Production Scheduling

Market / Customer driven production

Market / Customer demand
Classical Enterprise

Production Schedule

Product Development

Resources Engineering

Agile Enterprise
Market / Customer demand
Production Schedule Production Schedule

Product Develoment

Resources Engineering

Enterprise System 1

Manufacturing Control System 1 Manufacturing Control System 2

Company 1 with manufacturing

Enterprise System 2 Company 2 with No manufacturing

Manufacturing Control System 3 Company 3 Contract manufacturer

S95.01 Scope
Level 4

Level 3

Business Logistics Business Planning & Logistics Systems (ERP)

Plant Production Scheduling, Operational Management, etc

Interface addressed in ISA 95.01 / 02 dS95.03 Area S88

Manufacturing Operations Support Levels (MES) Batch 2,1,0 Discrete Continuous

Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

Manufacturing Operations & Control

Control Systems

Control Systems

Control Systems

Source: ISA dS95.01 Enterprise/Control System Integration

Manufacturing in The Supply Chain

The Supply Chain
The network of activities in a company that take place from customer order to customer delivery
Order Entry Suppliers
Customer

Delivery

Scheduling

Suppliers
Suppliers

Production

Distribution

S95/S88 and The Supply Chain

Suppliers

Enterprise Resource Planning / Supply Chain Management

Materials Product Production Manufacturing Operations Purchasing Development Planning Distribution & Logistics Customer Order Management Service

SP95.01 Enterprise / Control System Integration

R C R R C C

Recipe Management
A

Production Planning and Scheduling

Production Information Management

E

Process Management

Order & Inventory Management

Unit Supervision

Maintenance Management

Warehouse & Transportation Management

Process Control

Process Management

Consumers

S88 et S95
Enterprise A Product Enterprise B Product

S88
S95

S88

Enterprise X Manufacturing S88 Process Cell X1 S88

Quality

Enterprise Y Manufacturing S88 S88 Process Cell Y2

S95 Process Cell X2 Maintenance Process Cell Y1

S95.01 Production Schedule Structure

Production Schedule
A Production Schedule is made up of 1..n Production Requests

Production Request
A Production Request is made up of 0..n Segment Requirements

Segment Requirement
A Segment Requirement may contain 0..n of each

Production Personnel Parameter Requirement

Material Material Equipment Consumed Produced Requirement Requirement Requirement

Consumable Expected

Mixed Format Schedule Application

S95.01 Production Schedule

Work Dispatching

Setpoints & Flowpaths

S88.02 Schedule Entry

Setup Instructions

Continuous Premix

Batch Production Discrete Process Packaging

S95 in Production System Lifecycles

Production Schedule

Segment Requirement Product Definition Product Segments Process Segments Production Capabilities

Product Development

Resources

Resources Engineering

S88 in Production System Lifecycles

Production Schedule

S88 : Schedule

S88 : Recipe S88 : Equipment Procedural Elements

S88 : Resources

Product Development

Resources Engineering

ISA 95 : Enterprise Production Communication

What is ISA95 ? Status

SP95 committee started in October 1996 ANSI/ISA95.00.01 available from ISA
Submitted to IEC/ISO Joint Working Group (JWG 15) to be established Out for committee ballot and public comment
Still under development in the committee Developing XML Schemas for the exchanged information

ISA 95.00.02 in draft, out for vote ISA 95.00.03 in draft

World Batch Forum

Some SP95 Committee Members / Supporters

Users Eli Lilly Dow Corning Rohm & Haas Bayer Merck UOP Vendors ABB SAP ABB Honeywell Marcam GSE System HP General Purdue MESA KPMG DuPont Ben & Jerry's Sterling IBM Nestle Lyondell Chemical Novo Nordisk Tava Technologies Aurora Biosciences Pharmacia Lubrizol Bechtel EastmanK Genemtech Procter&Gamble

AspenTech Sequencia Rockwell FRSI OSI IBM GS Fluor Daniels PDXI MIT

Siemens InCode Yokogawa Foxboro InCode Intellution Microsoft AMR NAMUR PWC LLC

BaseTen Wonderware Propack Data Oracle Schneider Electric ORSI Jacobs Keops

Why Did We Start SP95 ?

Integration of business (logistics) systems to manufacturing is hard to do
Different systems, cultures, terminology... Many benefits expected from standardization and documentation of best practices

Effective operation of manufacturing is hard to do

MES solutions are too related to processing methods and too industry-specific Many benefits expected from standardization and documentation of best practices

Business Defines the Need

There must always be a business need for information to be exchanged Requirements for exchanged information are always driven by business needs & business processes Typical Business Drivers:
Available To Promise Reduced Cycle Time Supply Chain Optimization Asset Efficiency Agile Manufacturing

How Does S95* Help?

Separate the business processes from the manufacturing processes
Allow changes in production processes without requiring unnecessary changes scheduling and logistics processes
Alternate Logistics Strategies
Make to Order Make to Stock Engineer Configure to to Order Order

S95.01
PDXI NAMUR Continuous Manufacturing Models

S88.01
Batch Manufacturing Models

SME
Discrete Manufacturing Models

Provide a clear demarcation of responsibilities and functions Provide a clear description of exchanged information

Alternate Manufacturing Strategies

* S95 is used as a short form for ANSI/ISA95

Scope of S95.01
The definition of the scope of the manufacturing control domain A definition of the functions associated with the interface between control functions and enterprise functions A definition of the information which is shared between control functions and enterprise functions Based on the Purdue Reference Model for CIM and MESA model

SP95.01 Enterprise / Control Functional Model (PRM)

Production Scheduling (2.0)

Order Processing (1.0) Product Shipping Admin (9.0)

Product Cost Accounting (8.0)

Product Inventory Control (7.0) Production Control (3.0) Quality Assurance (6.0) Material and Energy Control (4.0) Marketing & Sales
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org

Procurement (5.0)

Maintenance Purchase Order Requirements

Research Development and Engineering

Elements of Models & Definitions

Domain Definitions (Responsibility) Functions in Domains Functions of Interest

Information Definitions

Categories of Information

Information Flows of Interest

Identified Information Categories

Data flow information was categorized Multiple Venn diagrams used to illustrate the overlap of information categories Enterprise Information
Plant Production Scheduling, Operational Management, etc

Production Product Production Production Capability Definition Schedule Performance InformationInformation (What to (What was
(What is available for use) (How to make a product) make and use) made and used)

Area Supervision, Production Planning, Reliability, Assurance, etc

Manufacturing Control Information

Major Object Definitions

Resources Capability, Product, Production

Product

People

Time

Capabilities

Equipment

Product Definitions

Materials

Production Schedule

Segments

Production Performance

Four Resource Object Models

Personnel resources managed for production
People

Equipment resources managed for production

Equipment

Material resources managed for production

Materials

Business view of production processes

Process Segments

Material Definition Example

Common material information
Material Class Acid Material Definition HCl 50% Lot HCL-50-100019 Sublot HCL-50-100019 Barrel 15

pH

Density

Color Purity

QA Test Results

Location QA Test Specification

pH 7.0

Density Color Purity 1.32 Yellow .5%

Process Segments
Business view of production

Assembly

Inspect

Paint

I-Beam Laborer 3x 8 hour

Type = Stainless Steel

Inspector 2x .25 Hour

Mixing Cans

Rollers Certified Painter = TRUE

Capability, Product, and Production Information

What is available for use for production
Product

Time

Capabilities

What is needed to make a product

Product Definitions

What to make and resources to use

Production Schedule

What was made and resources actually used

Production Performance

Capability Models
Product

People

Time

Capabilities

Equipment

Materials

Segments

Per Product Definitions

Scheduling System
Bill Of Resources e.g. 10 Speed Bicycle Product Segments

Material System
Bill Of Materials e.g. 10 Speed Bicycle

Frame Assembly

Final Assembly

Paint

Production Rules e.g. 10 Speed Bicycle

Color

Manufacturing Bill Frame : 1 Wheels : 2 Chain : 1 Seat : 1 Handlebars :1 Brake Pads : 4 ...

Frame Type

Seat Height

Manufacturing System

Production Schedule

People

Equipment

Product Definitions

Materials

Production Schedule

Segments

Production Performance
People

Equipment

Product Definitions

Materials

Production Schedule

Segments

Production Performance

Four Models & Segment Resources

Production Capability
What resources are available

Process Specification
What can be done with the resources

Product Definition
What must be defined to make a product

Production Scheduling
What is it to be made & used

Production Information
What was made & used

Production Schedule Production Rule Production Capability

Resource Capability

Production Performance Production Response Segment Response

Resource Actual

Production Request Segment Requirement

Resource Requirement

Process Segment
Resource Segment Capability

Product Segment
Resource Specification

Capability Property

Segment Property

Specification Property

Requirement Property

Actual Property

ISA 95.00.02 : Relationship with Part 1

ISA95.01
Equipment model

dISA95.02
Equipment Attributes

Attribute Name

Description

Examples

ID

A unique identification of a specific piece of R7726 equipment, within the scope of the information Reactor 101 exchanged (Production Capability, Production Lathe machine 33 Schedule, Production Performance, ) The ID is used in other parts of the model when the equipment must be identified, such as the production capability for this person, or a production response identifying the equipment.

Description

Additional information about the equipment.

ISA 95.00.03 : Level 3 Functions

MESA Definitions Operations and Detailed Scheduling Production Tracking Dispatching Production Resource Allocation and Control Data Collection and Data Acquisition Quality Management Process Management Performance Analysis Interface to
Document Control Labor Management Maintenance Management

d95.03 Definitions Detailed Production Scheduling Production Tracking Production Dispatching Resource Management Historical Data Management (QA) Product Analysis Process Analysis Production Analysis Product Definition Management Process Monitoring Manual Operations Automated Control

d95.03 Manufacturing Operations Functions

Product Definitions Production Capability Production Schedule
Detailed Production Scheduling

Production Performance

Resource Management Production Dispatching

Product Definition Management

Production Tracking (QA) Product Analysis

Historical Data Management

Process Analysis Production Analysis

Production Execution

Process Monitoring

Manual Operations

Automated Control

ISA 88 : Modular control

What is ISA 88 ? - Status

Standard ANSI/ISA 88 Batch Control Comit SP88 lanc en 1988 Partie 1 ISA 88.00.01
Publie et disponible lISA et lANSI IEC 61512-1 bilingue disponible auprs de lIEC, lUTE et lAFNOR Publication imminente Version IEC (61512-2) bilingue pour 2001? Dbut des travaux

Partie 2 ISA 88.00.02

Partie 3 ISA 88.00.03

Automation Challenge
Ideal automation

Flexibility
S88

Manual Operation

Capability

Darin Flemming Lou Pillai

Traditional Automation

Complexity

The Powerful Tyrex

Big brain Centralized design OK for steady / slow changing environment Shortcomings
Agility Availability

Refer to first computerized systems

vs Stupid Bird
Limited intelligence Mostly decentralized design
Local decision making at feather level Cope well with unexpected situations Inherently adaptative structure

From Goal to Labor

Forecasting, Planning And Scheduling The Goal: I know What/How To do Process Control Definition Equipment Functional Capabilities Elementary Equipment Control

Flying chirping Eating Love.

Walking

Scheduling hierarchy
Business system ISA 95

MES systems SCADA systems

ISA 88 IEC 61512 OPC

Process Control

Equipment Control

IEC 61131 IEC 61499

IEC 61158 Fieldbus

Intelligent Device

Product Processing / Equipment Control

Equipment allocation

Process Control
Production schedule How to make the product using available services?

Equipment Control
How to provide the expected services taking care of safety ?
IEC 60848 IEC 61131 IEC 61499 IEC 61508 IEC61158

ISA 88

R&D

ISA 88.00.02 (PFC)

ISA 88 Physical Model

Enterprise
May contain

Site
May contain

Area
May contain

Process Cell
Must contain

Unit Equipment
May contain

Equipment Module
May contain May contain

Control Module

May contain

Equipment Entities -An Object Approach

Physical Equipment
Equipment Entities

Equipment Control

Instruments Basic control Coordination control Procedural control

Example of physical modeling

Process Cell Unit Unit

EM
EM CM CM

EM

EM

CM

CM

CM

CM

Example of control modules

CM4

CM2 CM1 D1 PID D3 PID

D4 PID

CM3 D5 D2 HIC HIC

Why Control Modules

Treating as a control module simplifies the interface to this group of objects
Commands
Circulate Pump to Process Stop Shutdown
FC Pump FO

Status
Circulating Pumping to Process Stopped Shutdown

Recipe/Equipment Control Separation

Control Recipe Procedure
Recipe Procedure Procedure
is an ordered set of

Equipment Control

[Must Always Exist]

Unit Procedure
is an ordered set of

Operation
is an ordered set of

Phase

Equipment Phase

Recipe/Equipment Control Separation - Typical

Control Recipe Procedure
Recipe Procedure
is an ordered set of

Equipment Control

Recipe Unit Procedure

is an ordered set of

Recipe Operation
is an ordered set of

Recipe Phase

References

Equipment Phase

Recipe/Equipment Control Separation Alternate 3

Control Recipe Procedure
Recipe Procedure References

Equipment Control
Equipment Procedure
is an ordered set of

Equip. Unit Procedure

is an ordered set of

Equipment Operation
is an ordered set of

Equipment Phase

Phase Interface Logic

State machine enforcement between recipe phase and equipment phase

A set of services that support commands to the equipment phase

A set of services that support requests from the equipment phase to the recipe phase
Recipe Phase
Phase Interface Logic

Equipment Phase

Phase Interface Logic

Parameters Requests

Commands

State Machine

States

Phase Object
Parameters Start Hold Pause Aborting Pausing Data Run Held Paused

Stop
Abort Reset Resume Restart

Stopped
Aborted Idle

Holding

Running

Stopping

Data Collection Requirements

Completed

Control Action Status

Restarting Control Steps

Example Procedural Element States

Restart Complete Reset Hold

Restarting

Held

Holding

Idle (Initial State)

Start

Running Abort Stop

Pause Resume

Pausing

Aborting

Stopping

Paused

Aborted Reset

Final States Stopped Reset Quiescent States Transient States

Exception Handling In Control Actions

The safety interlock logic takes precedence over phase logic or process interlock logic. Typically this logic, when required, is implemented in an independent safety interlock system.

Safety Interlock Process Interlock

Control Module

Exception Logic

Control Module

The process interlock logic takes precedence over phase logic and manual override logic. Typically, this logic is implemented in the DPCS.

Phase Logic
Equipment Module

Control step (command)

Control Action

Field I/O
Control Module

Control Module/Control Action State/Mode

Inhibit manual override (Interlock from phase logic), Also sent to console to inhibit choice of manual mode

Console Control
Control Module/Control Action State/Mode Exception Logic

Inputs to Control Action Logic: - Set manual mode - Command from operator's console

ISA 88.00.02 : Procedural Function Chart

Tank A, B or C

Unit procedure interactions Relative timing

Height of unit procedure symbol Vertical placement of symbols Master recipes do not contain absolute timing
Arrowheads indicate material transfer

Preparation
S1

Reactor 1 or 2 operator input = OK to start

Initialize

Reaction
Charge

S1

Sample

Synchronization points
Initialize
T1 T1

S1

Sample OK
Transfer to Reactor
T1 T1

Receive from Prep.

React

Multiple levels of procedures

Encapsulation (contents) of unit procedure revealed Provides more detail

Transfer to Storage

THANK YOU