Mesatutorial - Isa95 Enterprise Integration

PracticalApplicationsof theISA95standard
DennisBrandl BR&LConsulting
MESAKNOWS
SUSTAINABILITY&ECOEFFICIENCY LEAN METRICS&PERFORMANCEMANAGEMENT INFORMATIONINTEGRATION SAFETY ASSETPERFORMANCEMANAGEMENT B2MML QUALITY&COMPLIANCE PRODUCTLIFECYCLEMANAGEMENT AUTOMATION
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DennisBrandl
DennisBrandlhasbeenanactivememberofISAsSP88 y committeesince1990,aU.S. BatchControlSystem expertinbatchcontroltoIEC,editoroftheISA95 EnterpriseControlSystemIntegrationstandard,and conveneroftheIECSC65EJWG5workinggroup. Hehasbeeninvolvedinautomationsystemdesignand implementationforthepast30yearsincludingApollo andSpaceShuttletestsystemsforRockwellSpace Division,aswellasworkwithShellOil,Texas Instruments,Siemens,SquareD,Sequencia, Telemecanique,Modicon,Pfizer,Lilly,Merck,GSK, Genentech,P&G,DOW,andotherprocessindustry companies. DennishasaB B.S. S inPhysics Physics,anM M.S. S inMeasurement andControlfromCarnegieMellonUniversity,andan M.S.inComputerSciencefromCaliforniaState University.
Copyright2012,MESAInternational
ThepowerofknowingwhatMESAKNOWS
Agenda
IntroductiontoISA95&MES AdvantagesoftheISA95standard MostimportantmodelsofISA95 PracticalapplicabilityoftheISA95modelsfor end dusers,consultants lt t and dengineers i Practicalexamplesanddescriptionsoftypical applicationstructures Questionsandanswers
WhatisISA95
USAANSIstandarddevelopedbyanISACommitteeofvolunteerexperts ANSI/ISA95.01ed2Enterprise ControlSystemIntegration Part1:ModelsandTerminology ANSIISA95.02ed2Enterprise ControlSystemIntegration P t2: Part 2 Objects Obj t and dAtt Attributes ib t ANSI/ISA95.03ed2Enterprise ControlSystemIntegration Part3:ModelsofManufacturingOperations ANSI/ISA95.04ed1Enterprise Enterprise ControlSystemIntegration Part4:Objectsandattributesformanufacturingoperationsmanagement integration ANSI/ISA95.05ed3Enterprise ControlSystemIntegration BusinesstoManufacturingTransactions AlsoavailableasIEC/ISO62264standards
ABitOfHistory
PriortoISA95
MESwasnotawelldefinedarea area,slowgrowthindeployments MESwassometimeviewedasasolutioninsearchofaproblem Hardtointegratewithbusinesslevelsystemsandshopfloorcontrol Very, y,very, y,very yindustry yspecific p Nocommondefinitionsorterminology
AfterISA95
RedefinedMESasMOM(ManufacturingOperationManagement) MOMactivitiesarewelldefined Standarddefinitionsandterminology,commonrequirements Wellunderstoodandsupportedbusinessleveltoshipfloorcontrol i t integration ti Morecrossindustrysolutionsbecomingavailable Significantcompetitionandadvancesinsolutions Rapidgrowthindeployments
ExampleBenefitsfromMES/MOM*
BenefitCategory DocumentReview i Approval l(SOPs) (SO ) BatchRecordPreparation&Handling BatchRecordReview DataEntry&Calculations Deviations LogbookHandling MaterialLosses Testing InventoryCarryingCosts Throughput RANGEOFTOTALANNUALBENEFITS RangeofBenefits $ 00 000 $3Million $100,000 illi $11,000 $1.3Million $115,000 $1.0Million $20,000 $4.6Million $6,000 $1.3Million $7,000 $105,000 Valueofpreventablediscards Preventabledeviationstesting ReducedInventoryCarrying $valueofadditionalbatches $450,000 >$10Million ReductionRange 10% 0% 80% 40% 80% 40% 80% 40% 90% 25% 60% 25% 80% 30% 60% 30% 50%
* CBINet Conference,INDUSTRYBESTPRACTICESFORMESARCHITECTURE,August2009,KeyConsiderationsfor MESProjectPlanningandExecution,Michalle AdkinsandPaulBrandenburg(Lilly)

TheAdvantagesoftheISA95Standard
Commonterminologyanddefinitionoffunctions
Simplifieswritingrequirementsforendusers Simplifiedvendorunderstandingofenduserrequirements
IntegrationofERPwithMES/MOMsystems
Prior i toISA95,projects j took k12years&<50% %successful f l AfterISA95,projectstake24months&>90%successful
DefinitionofMES/MOMsystems
PriortoISA95,specificationtookyearstoreachagreement AfterISA95,typicalspecificationscompletein<6months Possibletocomparedifferentvendorsolutions
Bettermatchtorequirements
Possibletocomparedifferentfacilities
MostImportantISA95 Models
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LevelsandFunctions
Level4
BusinessPlanning &Logistics
Plant Production Scheduling, Operational Management, etc
4 - Establishing the basic plant schedule production, material use, delivery, and shipping. Determining g inventory y levels. Time Frame Months, weeks, days, shifts
Level3
Manufacturing OperationsManagement
Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Time Frame Shifts, hours, minutes, seconds
Level2
ManufacturingControl
Level1 Level0
BasicControl,SupervisoryControl, ProcessSensing,ProcessManipulation,
2 - Monitoring, supervisory control and automated control of the production process 1 - Sensing the production process, manipulating the production process 0 - The physical production process
ProductionProcess
ISA95DomainDefinitions
Providesamethodtoanswerthequestion;
Whatisinlogistics and whatisinoperations p ?

What Wh tis i in i Level L l4orLevel L l123?
CriteriaforLevel3,2,1
ActivitiestobeincludedinLevel 3,2,or1aredirectlyinvolvedin manufacturingandincludesinformationaboutpersonnel, equipment,ormaterialandmeetsanyofthefollowingconditions.
Theactivityiscriticaltoplantsafety. Theactivityiscriticaltoplantreliability. Theactivityiscriticaltoplantefficiency.
NOTE:Absoluteplantefficienciesmaybedependentuponfactorsthatareoutsidethecontrolofafacility(MRP schedules,productmixes,etc.).
Theactivityiscriticaltoproductquality. The Th activity ti it i iscritical iti lto t maintaining i t i i regulatory l t compliance. li

EXAMPLE:Maintainingregional,governmentandotheragencycompliancerelatedtoproductsandproduction. NOTE:Thisincludessuchfactorsassafety,environmentalandcGMP (currentgoodmanufacturingpractices)compliance. NOTE:Thereareothercriteriasuchascompanypolicyandorganizationalstructure,orthenatureoftheoperationsthatcould expandthescopeofmanufacturingoperationsmanagement management. NOTE:Suchactivitiesaspersonnelmanagementofsalariesandjobtitlesmaybeimportantforrunningamanufacturing business,buttheyarenotconsideredpartofmanufacturingoperationsmanagement.
LevelOverlapwithSystems
Level4
BusinessPlanning Business Logistics &Logistics S Production Systems t (ERP) Plant Scheduling,

Operational Management, etc
4 - Establishing the basic plant schedule production, material use, delivery, and shipping. Determining inventory levels. Time Frame Months, weeks, days, shifts
Manufacturing Operations Manufacturing OperationsManagement Management Systems Dispatching Production, Detailed Production Time Frame Scheduling, Reliability Assurance, ... (MES, Batch, LIMS, AM, Shifts, ) hours, minutes, seconds
Level2 Level1
Level3
3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.
Control Systems (PLC, DCS, OCS, ) ManufacturingControl BasicControl,Supervisory Control, Intelligent devices ProcessSensing,ProcessManipulation, (Vision, Flow,
2 - Monitoring, g supervisory p y control and automated control of the production process 1 - Sensing the production process, manipulating the production process
Discrete, Continuous Level0 Batch,Production 0 - The physical production process Process

ISA95FormalModels
Interfacestobusinesssystems(ERP,MDM,PLM)throughXML dWBFB2MMLS d d( bf ) and Standard (www.wbf.org) StandardmodelforMOMtasksandactivities
ProcessSegments
DefinestheBusinessView ofproduction
PharmaceuticalManufacturingExample (3Segments)
Make Active Ingredient g Make Pills Package Doses
Raw Materials
Finished P d t Products
Inventory tracked for Active Acti e Ingredient
Inventory tracked for Pills
Inventory tracked for Pill Packs
Know throughput, resources and time to make Active Ingredient
Know throughput, resources and time to make Pills
Know throughput, resources and time to make Pill Packs
IntegrationModels
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EnterpriseIntegration ISA95& B2MML

Integrationofbusinesssystemstoshopfloor systemsisanimportantfinalphaseinanERP implementation
Companies p arediscovering gthatthetruevalueina logisticssystemonlycomeswhenitisconnectedto realworldshopfloorinformation.
TheISA95andIEC62264standardsdefinethe standardterminologyforbusinessto manufacturingintegration TheWBFB2MML(BusinesstoManufacturing MarkupLanguage)definesanimplementation emergingasthepreferredintegrationmethod

HowDoesISA95&B2MMLHelp?
ISA95Part1,Part2,andPart5
Providesacleardescriptionofexchangedinformation
Doesnotusevendorspecificterminology
Eachpieceofexchangedinformationhasanunambiguous meaning
UsesaPropertymodeltodescribecompanyspecificexchange information
Allowsseparationofbusinessprocessesfrommanufacturing processes
Allowschangesinproductionprocesseswithoutrequiring unnecessarychangestoschedulingandlogisticsprocesses
B2MML
DefinesanimplementationoftheISAmodelsinanXMLformat Definesastandardlanguageforrepresentingexchanged information
ISA95&B2MMLDataModels
Is assembled from Is assembled from Is assembled from Is assembled from 0..n 0..n Defines a gro uping 0..n 0..n 0..n 1..1 Defined by 0..n Made up o f 0..n 0..n
Material Class
Has pro perties of
0..n
Material Definition
Has pro perties of
Material Lot
0..n
Material Sublot
0 n 0..n
Is tested by a >
Is tested by a > 0..n 0..n 0..n
Is tested by a > 0..n
Has values for
Has values fo r
May be made up of sublots
Material Test Specification

0..n Defines a procedure fo r obtaining a 0..n Records the execution of
Is tested by a >
0..n Is tested by a > 0..n
QA Test Result
0..n
0..n
0..n 0..n
Material Class Property

0..n < may co ntain nested
May map to
Material Definition Property

0..n < may con tain nested
0..n Maps to
Material Lot Property
0..n < may co ntain n ested
Attribute Name ID
Description A unique identification of a specific material class , within the scope of the information exchanged ( production capability , production schedule , production performance , ) Additional information about the material class .
Production Examples Polymer sheet stock 1001A
Maintenance Examples 200 cP Oil (SAE 90)
Quality Examples RH5510
Inventory Examples 20 mil Wrap
Description
Solid polymer resin
Very High Viscosity Lubricating Oil Physical
Oxidizing Agent
Wrap used to wrap pallets Physical
Assembly Type Assembly Relationship
Optional: Defines the type of the assembly assembly. Optional: Defines the type of the relationships .
Physical
Logical
Permanent
Transient
Permanent
Transient
ExchangedLevel34Information
EnterpriseInformation
PlantProductionScheduling, OperationalManagement,etc
Resource Information
(Personnel, Equipment, PhysicalAsset, M Material Material, i l Segments)
Operations Capability Information

(Whatisavailable foruse)
Operations Definition Information

(Howtomake aproduct)
Operations Schedule
(Whattomake andwhat touse)
Operations Performance
(Whatwasmade andwhatwas used)
Manufacturing ControlInformation
AreaSupervision,ProductionPlanning, Reliability,Assurance,etc MostUsed ExchangesToday

MaterialInformation
Whatisshared MaterialMaster&MaterialInventoryinformation
Material Class HCl A Acid id Material Definition HCl 50% Lot HCL 50 100019 HCL-50-100019 Sublot HCL 50 100019 HCL-50-100019 Barrel 15
pH
Density
Color Purity
MaterialTest Results
MaterialTest Specification
L Location i
pH 7.0
Density Color Purity 1.05 Straw 99.5%
MaterialInformation
MaterialMaster
Represented dinMaterial lDefinition f &Material l Class Usually ysentfromERP(SAP) ( )toMOMsystems y
Triggeredbychangestomaterialmastersorchangessenton aregularbasis(everyshift,onceaday,)
Widely yusedinMOMactivitiestoidentify ymaterials
MaterialInventory
RepresentedinMaterialLot&MaterialSublot Containsquantity,location,statusinformationand companyspecificproperties
Example:pH,octane,Usebydate,QAstatus,
MaterialInformation ISA95Model
Exchangeinformationaboutpropertiesof materiallots, lots sublots, sublots definitions, definitions andclasses
Is assembled from Is assembled from Is assembled from Is assembled from 0 n 0..n 0 n 0..n Defines a grouping 0..n 0 n 0..n 0..n 1..1 Defined by 0 n 0..n Made up of 0 n 0..n 0 n 0..n
Material Class
Has properties p p of
0..n
Material Definition
Has properties p p of Is tested by a >
MaterialLot
0..n
Material Sublot
0..n
Is tested by a >
0..n 0..n 0..n
Is tested b a> by 0..n
Has values for
Has values for f
May be made up of sublots
MaterialTest Specification
0..n Defines a procedure for obtaining a 0..n Maps to Records the execution of
Is tested by a >
0..n Is tested by a > 0..n
Q Test QA Result
0..n
0..n
0..n
Material Class Property

0..n < may contain nested
May map to
Material Definition Property

0..n
MaterialLot Property
0..n
MaterialInformation B2MML Document

<Material> <MaterialLot> <ID> W89 </ID> <Description> A lot of material </Description> <MaterialDefinitionID WXE908 WXE908 /> <Location> Tank 1 </Location> <Quantity UnitOfMeasure = "KL KL" > 4500 </Quantity> <MaterialLotProperty> <ID> dateTimeProduction </ID> <Value> 2001 2001-01 01-06T00:14:23+11:30 </Value> </MaterialLotProperty> <MaterialLotProperty> <ID> Quality Status </ID> / <Value> Good </Value> </MaterialLotProperty> </MaterialLot> </Material>
RoleBasedEquipmentInformation
Exchangeinformationaboutpropertiesofspecificequipmentandequipment classes Thespecificpropertiesaredefinedbytheenduser
Example:Validatedforspecificequipment,inuse,sterile,benchmarkcapacity,heattransfer efficiency,
< May be made up of 0 0..n
Equipment Class
Has properties p p of >
0..n 0..n 0..n Is tested b an > by 0..n < Defined by 0..n
Equipment
Has values for >
Is tested b an > by 0..n
Equipment CapabilityTest Specification

0..n 0..n Is tested by an > 0..n Defines a procedure for obtaining an > 0..n Maps to 0..n < Records the execution of 0..n
Equipment CapabilityTest Result
Equipment ClassProperty
Equipment Property
PhysicalAssetInformation
Exchangeinformationaboutpropertiesofspecificphysical assetsandphysicalassetclasses Thespecificpropertiesaredefinedbytheenduser
Example:Inmaintenance,lastuseddate,stockpower,
> May be made up of 0..n > is an instance of 1..1 0..n 0..n Has values for > Is tested I d by an > 0..n 0..n Is tested I d by an > 0..n Has properties of >
Physical Asset
Physical AssetClass
Physical y Asset CapabilityTest Result
< records the t ti of testing f Defines a procedure for obtaining an < 0..n
PhysicalAsset CapabilityTest Specification

0..n 0..n Is tested by an < Maps to 0..n
0..n
0..n
Physical Asset Property

Physical AssetClass Property

OperationsSchedule
Whatactionstoperform
Materialstomake Priorityand/ordates Wh tmaterials What t i l t touse Whatequipmenttouse Whatpersonneltouse Productionparameters(e.g.Color,Options,)
PerSegment(stepinproduction) Perlocation(Site,Area,) week day day,shift, shift order, order Perweek,

SchedulingHierarchy
Business Plan (APICS)
(Per Business Area, Per Time)
M k ti Marketing Plan Pl (APICS)
(Per Product Family, Per Time)
ISA-95.00.01 - 1.1 Production Forecasting Activity
Production Plan ( (APICS) )

(Per Product, Per Time)
ISA-95.00.01 - 2.4 Production Scheduling Activity
Operations Schedule (ISA 95) - Master Production Schedule (APICS)

(Per Site, Per Product, Per Time)
ISA-95.00.03 Detailed Production Scheduling Activity
Work Schedule (ISA 95)
(Per Line, Per Product, Per Time)
ISA 95 95.00.03 00 03 - Production Dispatching Activity
Job List (ISA 95) & Batch List (ISA 88)

(Per Process Cell, Per Batch)
ISA 88.00.01 - Process Management Activity - ISA 95.00.03 Production Execution Activity
Work Directive (ISA 95) & Control Recipe (ISA 88)

(Per Unit, Per Batch)
OperationsSchedule
Operations Schedule
Is made up of 1..n May correspond to an <
Operations Definition
Operations Request
Is made up of May correspond to an < 1..n 0..n
Process Segment
Corresponds to an <
Segment Requirement
0..n May contain
Requested Segment Response
May contain
0..n
0..n
0..n
0..n
0..n
Segment Parameter
0..n May be made up of
Personnel Requirement
Equipment Requirement
PhysicalAsset Requirement
Material Requirement
0..n Is assem bled from
1..n
1..n
1..n
1..n
Personnel Requirement Property
Equipment Requirement Property
PhysicalAsset Requirement Property
Material Requirement Property
OperationsPerformance
Whatwasdone
Whatmaterialwasproduced&howmuch Whatmaterialwasconsumedorused&how much h Whatequipmentwasused&howlong What Wh tpersonnel lwereused d&h howl long
PerSegment(stepinproduction) Perl location( (Site,Area,) ) Perweek,day,shift,order,

ItTakesMoreThanJustSchemas
TheB2MMLstandarddefinesthestructureof integrationdata But,itdoesnotdefinethedetaileddefinition ofthesourceandtargetexchangeddata B2MMLprovidesatemplateorformat,much asablankcheck,butdoesnotspecifythe sourceordestinationofthedatainthe application li ti namespace Multiple methodsexistfordatamapping
AnXMLExample ProductionSchedule
Operation p Schedule Operation Request
Segment Requirement
Material Produced
ProductionPerformance MappedtoSAPPIPCSInterface
ProductionPerformance_Vimmerby_2002.vsd
MaterialProduced, MaterialConsumedtoSAP
DataMapping B2MMLMappingSpreadsheets
Documentmappinginformatsuitableforimplementation AvailableontheWBFwebsite
ISA95Part5 Transactions
Verb GET Description
Request to a receiver for information on one or more objects. The response is a SHOW message. The receiver returns a SHOW message containing all the specified attributes and all the specified contained elements of the specified nouns. If no attribute or contained element is specified in the noun area, then all attributes and/or contained elements shall be returned. When wildcards are applied to the noun and property IDs, it shall be possible to further filter th i the information f ti t to b be returned t db by specifying if i a value l f for one or more attributes tt ib t of f the th noun. Only objects whose attributes match the specified value (out of the list of objects matching the wildcards applied to noun and property IDs) shall be returned. Request to a receiver to process new information. The response is an ACKNOWLEDGE message. A new noun is added. Request to a receiver to remove information. The specified noun is canceled. Request to a receiver to change information. The response is a RESPOND message. The specified attributes and contained elements of the noun are changed. Request from the owner of the object to add information. Request from the owner of the object to change information. Req est from the o Request owner ner of the object to delete information information. Confirmation response to a request.
PROCESS CANCEL CHANGE SYNC ADD SYNC CHANGE SYNC DELETE CONFIRM
PushTransactionsinBusinessProcess
ERP Level4
Production Scheduling
PROCESS Production Schedule
MOM Level3
Somework complete Allwork kfi finished ih d
PROCESS Production Performance PROCESS* Production Performance
Scenarioassumptions: 1.ERPsendproductionscheduletoMOMforprocessing 2.MOM(ManufacturingOperationsManagement)sendsproductionperformancetoERPfor processing *MessagecontainsaFINALflagtoindicatethatthemessageisthefinalproductionperformance fortheassociatedproductionschedule schedule.
PushandPull ManageMaterialLotQuantity
ERP L l4 Level
Newmateriallot isavailable
MOM L l3 Level
GET Material Lot (ReceiptStatus = New) SHOW S O Material ate a Lot ot (qua (quantity t ty = 400) 00) CHANGE Material Lot (quantity = 300) CHANGE Material Lot (quantity = 200) CHANGE Material Lot (quantity = 0)
Materiallot quantitychanged Materiallot quantitychanged Materiallot quantitychanged
Scenarioassumptions: 1.MOMrequestsmateriallotinformationfromERP 2.ERPsendsinformationonnewmateriallots(lotswithnochanges) 3.MOMpushesquantitychangesinmateriallottoERP
ApplicationsNeedToTalk
ApplicationERP ApplicationMES
Integrationisapplicationtoapplicationdataexchange Acrossfirewalls, ,through g APIs, ,webservicesorflatfiles, , acrossawire,oftenindifferentlanguages,data formats,atdifferenttimecycles,ondifferentsystems, ofdifferentages, ages supportedbydifferentdepartments, departments y p providep partofthesolution ISA95andB2MMLonly
Integration TheCurrentSituation
Messagebasedprotocolshavebecomethestandardmodelforenterprise integration EnterpriseServiceBuses(ESB)havebecomethestandardmodelfor exchangingintegrationmessages XML hasbecomethestandardmodelfordatarepresentationwithin messages SOAP andREST havebecomethestandardinterfacestoESBs WebserviceshavebecomethestandardforSOAPimplementations p
Message
Application A
SOAP
XML
XML
REST
Application B
Application C
Enterprise Service Bus

SOAP
XML
XML
Web S i Service
Application D
Integration:TheHiddenComplexity
Everyintegrationprojectneedsthefollowingelements Some S communication i ti i isoneway
Application Thor
Thor Convert Local Data format to Store Global format
Convert Local names to Global names
Send information to ESB
ESB Server
Convert Global Application Apollo Data format to Local Apollo Store format
Convert Global names to Local names
Receive information from ESB
ESB Server
Integration TwoWayCommunication
Multipletranslations,copies,services, Somecommunicationistwoway
Convert Local format to Global format
Application Thor
Thor Data Store Convert Global format to Local format
Convert Local names to Global names Convert Global names to Local names
Send information to ESB Receive information from ESB
ESB Server
4 2
ESB Server
Handle Transaction Logic
Application Apollo Data Apollo Store Convert Local format to Global format
Convert Global format to Local format
Convert Global names to Local names
Receive information from ESB
Convert Local names to Global names
Send information to ESB
3
ManyLayersforIntegration
ConvertFormats(B2MML)
Fromlocaltoprojectselected common(canonical)formats Fromcanonicaltolocal format
LinktoESB
API, API WebService Service,
ExchangeMessagesacross ESB
IP IP,Internet Internet,Ethernet, Ethernet WAN WAN, VPN,,,,
ConvertNames (PlannedISA95TR.02)
Fromlocalnamestocommon names(tags ) (tags,status status,) Fromcommonnamestolocal names
TransactionLogic
Rulesforhandling gof messages
Send/Receivemessages (PlannedISA95TR.03)
PublishSubscribemethods Query yResponse p methods
1 6
B2MMLImplementations
Multiplepubliclydiscussedimplementations:
Nestle,ArlaFood,CerveceriaPolar,P&G AllhaveSAPasatleastoneoftheERPsystemsconnected
Technically
Thesolutionsarenotmuchdifferentfromeachother AllusingBusinessConnectorcombinedwithdifferent accesstoR/3:PIPCS,IDOCS,BAPIcalls,XI.
Allexperiencedsignificantimprovementsinintegration efforts
ForconnectiontodifferentERPsystems ForconnectiontodifferentMESandcontrolsystems
ISA95Part3 ModelsofManufacturing Operations

ThenewmodelforMES
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ISA95 4CategoriesofMOMActivities
ProductionOperationsManagement
Activities ct t est that atcoo coordinate, d ate,d direct, ect,manage a age&t track ac t the efunctions u ct o st that atuseraw a materials,energy,equipment,personnelandinformationtoproduceproducts
QualityOperationsManagement
Activitieswhichcoordinate,direct&trackthefunctionsthatmeasureand reportonquality
InventoryOperationsManagement
Activitieswhichcoordinate,direct&trackthefunctionsthatmanageandtrack theinventoryofproductand/ormaterialandtheirmovements
i i M M Maintenance O Operations Management

Activitieswhichcoordinate,directandtrackthefunctionsthatmaintainthe equipment,toolsandrelatedassetstoensuretheiravailabilityfor manufacturing
Modelshavealsobeenappliedto:
Shipping,Receiving,Transportation,
ModelsofProductionActivities&Data
Operation definition Resource information Operations capability Operations schedule
Detailed production scheduling Production resource management Production dispatching Product definition management Production P d i execution management
Equipment and process specific production rules Operational commands Operational responses Equipment and process specific data
Operations performance
Physical Assets
KPIs (ISO 22400)

Production tracking Production Performance analysis y Production data collection
Level 1-2 Functions

MaintenanceOperations
Maintenance definitions Maintenance capability Maintenance request
Detailed maintenance scheduling Maintenance resource management Maintenance dispatching Maintenance definition management Maintenance execution management
Equipment specific maintenance procedures Maintenance commands and procedures Maintenance results Equipment state of health data
Maintenance response
Maintenance tracking Maintenance analysis Maintenance data collection
Level 0-1-2 personnel & equipment
QualityTestOperations
Quality test definitions Quality test capability Quality test request
Detailed quality test scheduling Quality test resource management Quality test dispatching Quality test definition management Quality Q li test execution managent
Quality parameters and procedures Test commands Test responses Quality specific data
Quality test response
Quality test tracking Quality performance analysis Quality test data collection
Level 0-1-2 equipment

MaterialMovementandInventory TransferActivities
Inventory definitions Inventory capability Inventory request
Detailed inventory scheduling Inventory resource management Inventory dispatching Inventory definition management Inventory execution management
Inventory storage definitions Inventory commands Inventory replies Inventory specific data
Inventory response
Inventory tracking Inventory analysis Inventory data collection
Level 0-1-2 inventory equipment

AllOperationsCategories
Operations definition Resource information Operations capability Operations schedule Operations performance
Physical Assets
KPIs (ISO 22400)
E i t and d process Equipment specific production rules
O ti l Operational commands
O ti l Operational responses
E i t and d process Equipment specific data
Level 1-2 Functions
ISA95 RequirementsforMOM
TheISA95Part3standarddefinesabout>80%oftheactivitiesthat occurinManufacturingOperationsManagement(MOM)
ProductionOperationsManagement MaintenanceOperationsManagement Laboratory(Quality)OperationsManagement MaterialHandling&Storage(Inventory)OperationsManagement Supportingactivities
Managementofsecurity M Management tof fi information f ti Managementofconfiguration Managementofdocuments Managementofregulatorycompliance Managementofincidentsanddeviations
ActivitiesareusedasamaptoidentifyMOMrequirements
ISA95.03Format
Part3definesthetasks andactivitiesforall4 categoriesofMOM
Itisastraightforward processtoconvertthese intorequirements
MostMOM/MESusers areusingthisoutlineto generatetheirMOM requirements

Notallprojectscoverall categories Notallprojectscoverall activitieswithinacategory
Activitiesand Tasks
Standardliststasksthat y occurineachactivity Thestandarddoesnot specifyanarchitectureor organization Tasklistcanbequickly convertedinto requirements Identifywhichactivitiesare t be to b supported t d Identifywhichresources (equipment,personnel, material)aretobe supported Writerequirementsusing ISA95terminology
ISA95Part3 TemplateforUser RequirementSpecifications

Typicalenduser q (URS) ( ) requirements Beingusedtocompare differentvendors functionalityand capabilities Wefinallyhaveavendor independentdescription ofMOM/MES Wefinallyhaveacommon waytocomparedifferent facilities
MOMBoundaryDefinesthe Requirements Requirement sscope

Product definition Production capability Production schedule
Detailed production scheduling Production resource management Production dispatching Product definition management Production P d ti execution Production data collection Production P d ti analysis Production oduct o tracking (QA) Product analysis
Production performance
Level 2 Process Control
ForAllCategories
Determinewhichareasarecoveredbythe i l implementation t ti Mostimplementationscover1or2categories Determinethelineofresponsibilityforeachcategory
Maintenance
Maintenance Definitions Maintenance Capability Maintenance Schedule Maintenance Performance Product definition Maintenance Requests
Production
Production capability Production schedule Production performance Quality definitions Quality test capability Maintenance Responses
Quality
Quality test schedule Quality test performance Inventory transfer definitions Quality test requests
Inventory
Inventory transfer capability Inventory transfer request Inventory transfer response Quality test responses
Detailed Maintenance Scheduling Maintenance Tracking
Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking
Detailed quality test scheduling Quality test tracking
Detailed transfer scheduling Transfer resource management Transfer dispatching Transfer definition management Transfer execution Transfer data collection Transfer tracking
Maintenance Resource Management Maintenance Dispatching Maintenance Definition Management Maintenance Execution
Quality test resource management Analysis Quality test dispatching Quality definition management Quality test execution
Maintenance Analysis Maintenance Data Collection
Quality analysis Quality test data collection
Transfer analysis
Level 2
Example:Equipment/VesselTracking
Ataprocesscompanyonemainissuewastracking t transfer f vessels, l their th i status t t (clean, ( l sterile, t il in i use,) ) andlocation(inplantandbetweenplants) LimitedMESinstalledtotrackequipmentresources Reduceddelays y duetovessel availabilityand eliminatederrors duetoincorrect equipment
Example:Investigations&RFTStudies
Majorcompanysgoalwasreduceincident i investigation ti ti ti time&RFTstudy t d time, ti >80% 80%spent t collectingdata InstalledalimitedMESforDataCollection&Analysis
Initialimplementations havesignificantly reducedstudy andinvestigationtimes

TypicalInitialMESImplementation
Product definition Resource information Production capability Production schedule
Detailed production scheduling Production resource management
MES
Production dispatching
Production tracking Production Performance analysis Production data collection
Product definition management Production execution management
Historian
Level 1-2 Functions
TheTypicalMES/DCSPattern
Product definition Resource information Production capability Production schedule
Detailed production scheduling Production resource management
MES
Production dispatching
Production tracking Production Performance analysis Production data collection
Product definition management Production execution management
DCS
Level 1-2 Functions
CommercialMOM/MESSystems
MostlybasedonISA95andISA88standards Most M tsolutions l ti still tillf focused doni industry d t segments t
Pharmaceutical Automotive DiscreteAssembly FoodandBeverage ProcessIndustries
Siteimplementationsrangefrom200K 2MUSD dependingonscopeandcustomizationrequired Paybackscomefrom2%3%yeartoyearproductivity improvements

Becauseofability ytolockinbestp practicep procedures
Summary
ISA95providesavendorindependentdescriptionof MOM/MES Providesavendorindependentanduserindependent formatforMOMrequirements Verticalintegrationofsystemisusuallyrequiredto achievefullMOMbenefits WelldocumentedbenefitsfromMOM implementationsaredrivingadditional implementations MostvendorsaresupportingtheISA95standardand areusingittodescribetheirproductsfunctionality
ISA95/MOM/B2MMLQuestions

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Mesatutorial - Isa95 Enterprise Integration

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PracticalApplicationsof theISA95standard

* CBINet Conference,INDUSTRYBESTPRACTICESFORMESARCHITECTURE,August2009,KeyConsiderationsfor MESProjectPlanningandExecution,Michalle AdkinsandPaulBrandenburg(Lilly)

Whatisinlogistics and whatisinoperations p ?

Theactivityiscriticaltoproductquality. The Th activity ti it i iscritical iti lto t maintaining i t i i regulatory l t compliance. li

BusinessPlanning Business Logistics &Logistics S Production Systems t (ERP) Plant Scheduling,

Discrete, Continuous Level0 Batch,Production 0 - The physical production process Process

Inventory tracked for Active Acti e Ingredient

Inventory tracked for Pills

Inventory tracked for Pill Packs

Know throughput, resources and time to make Active Ingredient

Know throughput, resources and time to make Pills

Know throughput, resources and time to make Pill Packs

EnterpriseIntegration ISA95& B2MML

TheISA95andIEC62264standardsdefinethe standardterminologyforbusinessto manufacturingintegration TheWBFB2MML(BusinesstoManufacturing MarkupLanguage)definesanimplementation emergingasthepreferredintegrationmethod

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Material Test Specification

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Material Class Property

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Material Lot Property

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Production Examples Polymer sheet stock 1001A

Maintenance Examples 200 cP Oil (SAE 90)

Quality Examples RH5510

Inventory Examples 20 mil Wrap

Solid polymer resin

Very High Viscosity Lubricating Oil Physical

Wrap used to wrap pallets Physical

Assembly Type Assembly Relationship

Operations Capability Information

Operations Definition Information

AreaSupervision,ProductionPlanning, Reliability,Assurance,etc MostUsed ExchangesToday

Density Color Purity 1.05 Straw 99.5%

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MaterialInformation B2MML Document

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Equipment CapabilityTest Specification

Equipment CapabilityTest Result

Physical y Asset CapabilityTest Result

PhysicalAsset CapabilityTest Specification

Physical Asset Property

Physical AssetClass Property

PerSegment(stepinproduction) Perlocation(Site,Area,) week day day,shift, shift order, order Perweek,

M k ti Marketing Plan Pl (APICS)

(Per Product Family, Per Time)

ISA-95.00.01 - 1.1 Production Forecasting Activity

Production Plan ( (APICS) )

ISA-95.00.01 - 2.4 Production Scheduling Activity

Operations Schedule (ISA 95) - Master Production Schedule (APICS)

ISA-95.00.03 Detailed Production Scheduling Activity

Work Schedule (ISA 95)