Presentación ISA 95

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Presentación ISA 95

  1. 1. NORMA ISA 95 Enterprise-Control System Integration Standard B2MML Business To Manufacturing Markup Language
  2. 2. Companies Participating in SP95 <ul><li>ABB </li></ul><ul><li>Arla Foods </li></ul><ul><li>AspenTech </li></ul><ul><li>Dupont </li></ul><ul><li>Eli Lilly </li></ul><ul><li>Emerson Process Management </li></ul><ul><li>Fluor </li></ul><ul><li>General Electric </li></ul><ul><li>Invensys-Wonderware </li></ul><ul><li>Lighthammer </li></ul><ul><li>Lund University, Sweden </li></ul><ul><li>Lyondell – Equistar </li></ul><ul><li>Microsoft </li></ul><ul><li>Nestle </li></ul><ul><li>Novo Nordisk </li></ul><ul><li>Proctor & Gamble </li></ul><ul><li>Purdue University </li></ul><ul><li>Rockwell Automation </li></ul><ul><li>SAP </li></ul><ul><li>Siemens </li></ul><ul><li>Yokogawa </li></ul>
  3. 3. Why was ISA-95 Created? <ul><li>Integration of business and manufacturing systems is difficult </li></ul><ul><ul><li>Different Automation & IT cultures, knowledge bases </li></ul></ul><ul><li>Lack of consensus and models to follow for integration </li></ul><ul><li>Increase in business needs to integrate manufacturing sites with business systems </li></ul><ul><li>Business drivers: </li></ul><ul><ul><li>Supply chain optimization </li></ul></ul><ul><ul><li>Asset efficiency </li></ul></ul><ul><ul><li>Agile manufacturing </li></ul></ul><ul><ul><li>Available to Promise & Available to Profit </li></ul></ul>
  4. 4. What ISA-95 Offers <ul><li>Framework for integration projects </li></ul><ul><li>Separation of business processes from manufacturing processes </li></ul><ul><li>Focus on functions, not systems, organizations or individuals </li></ul>
  5. 5. ISA-95 Scope 95.03 SITE AREA AREA AREA CONTINUOUS PRODUCTION UNIT DISCRETE PRODUCTION LINE ENTERPRISE 95.01 & 2 BATCH PROCESS CELL
  6. 6. Information of Interest Functions Outside the Control Domain (e.g. Production Scheduling) (e.g. Production Schedule and Production Results) Information Flows of interest Functions Within the Control Domain (e.g. Equipment Monitoring) Enterprise/Control System Boundary Functions detailed Functions not detailed Data flows detailed Data flows not detailed
  7. 7. Categories of Information Production Response Production Schedule Business Planning & Logistics Information Production Definition Manufacturing Operations & Control Information Production Capability Resource Availability Manufacturing Instructions, Recipes, BOM, What to make, when to make it , what to use What was made and used
  8. 8. Major Object Models <ul><li>Three categories of resources </li></ul><ul><ul><li>Personnel </li></ul></ul><ul><ul><li>Equipment </li></ul></ul><ul><ul><li>Material (and Energy) </li></ul></ul><ul><li>Combined resources (logical view) </li></ul><ul><ul><li>Process Segments </li></ul></ul><ul><li>Four Models / Production-Process-Product </li></ul><ul><ul><li>Production Schedule </li></ul></ul><ul><ul><li>Production Performance </li></ul></ul><ul><ul><li>Capability Definition (by time & by segment) </li></ul></ul><ul><ul><li>Product Definition </li></ul></ul>
  9. 9. Design Patterns <ul><li>Resources </li></ul><ul><ul><li>Class-Instance models </li></ul></ul><ul><li>Major Objects </li></ul><ul><ul><li>Sub-divided into segments </li></ul></ul><ul><ul><ul><li>Each segment has personnel, equipment, material, & data components </li></ul></ul></ul><ul><li>Properties </li></ul><ul><ul><li>Few standard object attributes </li></ul></ul><ul><ul><li>Properties used to permit customization </li></ul></ul>
  10. 10. Necesidades de Importantes empresas del mundo + Experiencia de los Principales proveedores de soluciones tecnológicas = Norma ISA 95 Definición de Modelos
  11. 11. Niveles de Detalle del Modelo Parte 1: CL 5 Parte 1: CL 5 y 6 Parte 1: CL 6 Parte 1: CL 7. 3-4- 5 Parte 1: CL 7 Parte 1: CL 6.2
  12. 12. <ul><li>5 </li></ul><ul><li>Hierarchy Models </li></ul><ul><ul><li>5.1 Scheduling and control hierarchy </li></ul></ul><ul><ul><li>5.2 Equipment hierarchy model </li></ul></ul>
  13. 13. Scheduling and control hierarchy Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Batch Control Discrete Control Continuous Control Level 4 Level 3 Levels 2,1,0 Interface addressed Parts 1 & 2 Area addressed Parts 3 & 4
  14. 14. Equipment hierarchy model Level 3 activities typically deal with these objects ENTERPRISE SITE AREA PRODUCTION LINE WORK CELL PRODUCTION UNIT PROCESS CELL UNIT Level 4 activities typically deal with these objects Lower level equipment used in repetitive or discrete production Lower level equipment used in batch production Lower level equipment used in continuous production STORAGE ZONE STORAGE MODULE Lower level equipment used for storage Enhanced in Part 3
  15. 15. Functional data flow model <ul><li>6 </li></ul><ul><li>Functional data flow model </li></ul>
  16. 16. Reference Model OAGi General Meeting ISA-95 - B2MML Briefing May 2, 2006 Enterprise/ Control Boundary
  17. 17. Functional data flow model <ul><li>7 </li></ul><ul><li>Object Model </li></ul><ul><ul><li>7.1 Categories of information </li></ul></ul><ul><ul><li>7.3 Production capability information </li></ul></ul>
  18. 18. Identified Information Categories Manufacturing operations & control information Production operations, maintenance operations, quality operations, etc Business planning & logistics information Plant production scheduling, operational management, etc Product definition information (What must be defined to make a product) Production capability information (What resources are available) Production schedule information (What to make and use) Production response information (What was made and used)
  19. 19. 7.1.1Production capability information
  20. 20. 7.1.2 Product definition information
  21. 21. 7.1.2 Product definition information
  22. 22. 7.1.3 Production information
  23. 23. 7.1.4 Process Segment capabilities
  24. 24. 7.1.4 Process Segment
  25. 25. <ul><li>MODELOS </li></ul><ul><li>Objetos </li></ul>
  26. 26. 7.3 Production capability information
  27. 27. 7.3 Production capability information
  28. 28. Personnel Model Person Property Personnel Class Has values for 0..n 0..n 0..n 0..n 0..n 0..n 0..n 1..n Has Properties of Is tested by a Maps to Defined by Records the execution of Defines a procedure for obtaining a Person Personnel Class Property Qualification Test Specification Qualification Test Result
  29. 29. Persons and Personnel Classes Supervisor Laborer Professional Engineer Operator Pump Mechanic Draftsman Joe Smith - ID#12345 Sally Jones- ID#12344 Qualification Test Qualification Test Results
  30. 30. Equipment model Maintenance Work Order May be generated for 0..n 1..1 1..1 1..1 Equipment Property Equipment Capability Test Specification Has values for 0..n 0..n 0..n 0..n 0..n Equipment 0..n 0..n 1..n Has Properties of Is tested by a Maps to Defined by Records the execution of 0..n 0..n May result in 0..1 May be made up of Is against Is made against 0..n 0..n Defines a procedure for obtaining a Equipment Capability Test Result Maintenance Response Equipment Class Property Maintenance Request Equipment Class
  31. 31. Equipment and Classes Mixing Reactor Heating Reactor HR101 HR102 HMR101 MR101 MR102 Maintenance Request Maintenance Work Order Capability Test Capability Test Results Max Temp = 300 F Capacity = 5000 Gal Shearing = TRUE Capacity = 3000 Gal
  32. 32. Material model Material Sublot May be made up of sublots 0..n 0..n 0..n Material Definition Property QA Test Specification Material Definition Has values for 0..n 0..n 0..n 0..n 0..n Material Lot QA Test Result 1..1 0..n 1..n Has Properties of Is tested by a Maps to Defined by Records the execution of Made up of Material Class Property Material Class 0..n Has Properties of 0..n Defines a grouping Is associated with a May map to Defines a procedure for obtaining a Material Lot Property
  33. 33. Material Definition Example Lot HCL-50-100019 pH 1.0 Density 1.05 Color Straw Purity 99.5% Material Definition Material Definition HCl 50% Color Purity pH Material Class HCl Acid Material Class Density Sublot HCL-50-100019 Barrel 15 Location QA Test Specification QA Test Results
  34. 34. Process Segment Model Personnel resources managed for production Equipment resources managed for production Material resources managed for production Collections of resources, used together for production, at the granularity needed for business level scheduling and costing People Materials Equipment Segments
  35. 35. Process Segment Model
  36. 36. Process Segments <ul><li>Business view of production </li></ul>Inventory tracked for Active 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 Pharmaceutical Manufacturing (3 Segments) Make Active Ingredient Make Pills Package Doses Raw Materials Finished Products
  37. 37. 7.4 Product definition information
  38. 38. 7.5 Production information <ul><li>7.5.1 Production Schedule Model </li></ul><ul><li>7.5.2 Production Performance Model </li></ul>
  39. 39. Production, Capability, Product Production Schedule Production Performance What to make and resources to use What was made and resources actually used Product Definitions What is available for use for production What is needed to make a product Product Time Capability/Capacity
  40. 40. Production Schedule People Materials Equipment Segments Product Definitions Production Schedule
  41. 41. 7.5 Production Schedule Model Personnel Requirement Equipment Requirement Material Produced Requirement Personnel Model Equipment Model Material Model Corresponds to element in Corresponds to element in Corresponds to element in May contain 0..n 0..n 0..n 0..n 1..n Personnel Requirement Property Equipment Requirement Property Material Produced Requirement Property 1..n 1..n 1..n Production Schedule Process Parameter Material Consumed Requirement Corresponds to element in 0..n Material Consumed Requirement Property 1..n Consumable Expected 0..n Consumable Expected Property 1..n Segment Requirement 1..n Is made up of Is made up of Is associated to either Product Production Rule Requested Segment Response Corresponds to a Corresponds to a Production Parameter Production Request 0..n Process Segment Product Parameter
  42. 42. Production Performance Product Definitions Production Schedule People Materials Equipment Segments Production Performance
  43. 43. 7.5 Production Performance Model Personnel Actual Equipment Actual Material Produced Actual Production Data Personnel Model Equipment Model Material Model Corresponds to element in Corresponds to element in Corresponds to element in May contain 0..n 0..n 0..n 0..n 1..n Personnel Actual Property Equipment Actual Property Material Produced Actual Property 1..n 1..n 1..n Production Performance Production Response Material Consumed Actual Corresponds to element in 0..n Material Consumed Actual Property 1..n Consumable Actual 0..n Consumable Actual Property 1..n Segment Response 1..n Is made up of Is made up of Process Segment Corresponds to a
  44. 44. Resumen
  45. 45. Production Schedule Application <ul><li>Multiple levels of planning & scheduling </li></ul><ul><ul><li>Quarterly </li></ul></ul><ul><ul><li>Monthly </li></ul></ul><ul><ul><li>Weekly </li></ul></ul><ul><ul><li>Dispatch to Production </li></ul></ul><ul><li>Production schedules often must be split to multiple control systems & multiple process types </li></ul>ISA-95 Production Schedule Setpoints & Flowpaths Dispatching Setup Instructions Batch Schedule Continuous Premix Batch Production Process Discrete Packaging
  46. 46. ISA-95 Functional Hierarchy OAGi General Meeting ISA-95 - B2MML Briefing May 2, 2006 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Continuous Control Level 4 Level 3 Levels 2,1,0 Parts 1, 2 & 5 focus on this Interface Discrete Control Batch Control Parts 3 & 4 Focus on Manufacturing Operations
  47. 47. ISA-95 Part 3 Generic Model OAGi General Meeting ISA-95 - B2MML Briefing May 2, 2006 Data collection Execution management Resource management Dispatching Tracking Operations response Detailed scheduling Operations request Definition management Analysis Operations capability Operations definitions
  48. 48. 4 Sets of Level 3 Activities Resourse Management Quality Management Inventory Management Production Management data collection execution management resource management dispatching tracking Detailed scheduling definition management performance analysis data collection execution management resource management dispatching tracking Detailed scheduling definition management performance analysis data collection execution management resource management dispatching tracking Detailed scheduling definition management performance analysis data collection execution management resource management dispatching tracking Detailed scheduling definition management performance analysis

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