Professional Documents
Culture Documents
2003 09 IEE Cambridge V03
2003 09 IEE Cambridge V03
Management
Dennis Brandl
BR&L Consulting
Dennis Brandl
Peter Owen
Eli Lilly & Co
Objectives
Review the ISA 95 standards and how they are being
used in companies like Eli Lilly & Company for shop
floor to top floor integration
The standards provide a formal model for exchanged data
between business systems and manufacturing systems
The models also include a definition of Manufacturing
Operations Management, the activities on the shop floor that
take production schedules and perform the actual work
required to manufacture products
Model detail
Linear route structures
Control emphasis
Product cost and overall
profitability
Modeling criteria:
Accounting reference
points
Has inventory value
changed significantly? If
not, dont model
separately
Manufacturing Systems
Time Horizons
Real-time view
Model detail
Complex routes with
rework paths
Control emphasis
Physical movement &
accountability
Modeling criteria:
material movement
reference points
Does product stop
moving? If not, dont
model separately
Philosophical Orientation
Enterprise Management systems:
Where is my stuff?
ISA95.01 Levels
Level 4
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Interface addressed
in the ISA 95.01 and
ISA 95.02 standard
Area addressed
in the ISA 95.03
standard
Levels
2,1,0
Batch
Control
Continuous
Control
Discrete
Control
ISA95.01 Levels
Level 4
Business
Logistics
Business Planning
& Logistics
Management
(ERP)
Level 3
Plant Production Scheduling,
Operational Management, etc
Manufacturing
Operations & Control
Interface addressed
in the ISA 95.01 and
ISA 95.02 standard
Area addressed
in the ISA 95.03
standard
Manufacturing
Operations
Management
Levels
2,1,0
(MES, LIMS, AM, )
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Batch
Control
Continuous
Control
Discrete
Control
Dennis Brandl
10
(How to make
a product)
make and
use)
made and
used)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
Dennis Brandl & Peter Owen
11
Personnel
Equipment
Material (and Energy)
Process Segments
12
13
Time
Capability/Capacity
14
Production Schedule
People
Production Schedule
Production Request
Segment Request
Expected Produced Material
Expected Consumed Material
Expected Personnel
Expected Equipment
Production Parameters
Equipment
Materials
Segments
Dennis Brandl & Peter Owen
What to make
- Priority and/or dates
- What materials to use
- What equipment to use
- What personnel to use
- Production parameters
(e.g. Color, Options,)
Production
Schedule
Production Performance
People
Production Performance
Production Response
Segment Response
Produced Material Actual
Consumed Material Actual
Personnel Actual
Equipment Actual
Production Data
Equipment
Materials
Segments
Dennis Brandl & Peter Owen
Production
Performance
17
18
ISA95 Part 3
Activity Models of
Manufacturing Operations
In Development
Expected Release 2004
Dennis Brandl
19
Order
Processing
(1.0)
Production
Scheduling
(2.0)
Material and
Energy Control
(4.0)
Production
Control
(3.0)
INVENTORY
OPERATIONS
Product
Inventory Control
(7.0)
QUALITY
ASSURANCE
OPERATIONS
MAINTENANCE
OPERATIONS
Maintenance
Management
(10.0)
Product
Shipping Admin
(9.0)
PRODUCTION
OPERATIONS
INVENTORY
OPERATIONS
Procurement
(5.0)
Product Cost
Accounting
(8.0)
Quality
Assurance
(6.0)
Marketing
& Sales
Research
Development
and Engineering
20
Production
tracking
Production
dispatching
Analysis
Production
data
collection
Product
definition
management
Production
execution
Equipment and Process
Specific Production Rules
Operational
Commands
Operational
Responses
21
Major
Activities
Within
Manufacturing
Operations
Level 3
Inventory
Operations
Maintenance
Operations
Production
Operations
Management
of Information
Quality
Operations
Management
of Configuration
Management
of Security
Management
of Documentation
Management
of Compliance
Level 2
Activity detailed
Activity not
detailed
Activity outside
scope
22
Implementations
Nestle
Project to use the XML schemas for schedule
exchange
Arla Foods
Project to use XML for standard interfaces to
multiple ERP systems and MES systems
Empersas Polar
Project to use XML schemas for schedule
exchange
Eli Lilly
Projects to use ISA 95 models for manufacturing
operations management architecture
Dennis Brandl & Peter Owen
23
Conceptual Topology
Functional Areas
Standards and Guidelines
Standard Applications
Logical Architecture Design
Physical Architecture Design
24
Level 3
Business Logistics
Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
Manufacturing
Operations Management
Dispatching, Detailed Production
Scheduling, Production Tracking, ...
Level 2
Level 1
Level 0
Dennis Brandl & Peter Owen
ISA IEC/ISO
Interface
Standards
ISA
Functional
Model
Batch
Continuous Discrete
Production Production Production
Control
Control
Control
The production processes
25
Level 3
Maintenance of production information is centralized to
provide greater control and availability of the records
Electronic records are managed and controlled through
Level 3 systems with audit trail, access control, backup, and
ERP connectivity
Usually standard hardware and networks
26
Level 4
Business Process Information Network
Level 3
Operations Information Network
Level 2
HMI, SCADA,
Batch Systems
Automation Network
PLC, DCS,
Packaged Systems
Discrete & Process Device Communication Networks
Level 1
Dennis Brandl & Peter Owen
I/O, Devices,
Sensors
27
Functional Areas
Use the ISA 95 and ISA 88 models of functions
Map the functions to system areas and networks
Use the ISA 95 rules for determining what is in Level
3 (vs Level 4)
The function is critical to maintaining regulatory compliance.
Includes such factors as safety, cGMP, and environmental
compliance
28
Production Dispatching
Production Analysis
Level 2
Recipe Control
Supervisory Control
Alarm Management
Operator Visibility
Operator Control
Equipment Information Collection
Automation Network
On/Off Control
Continuous Control
Programmed Control
Phase Control
Level 1
Sense Events
Manipulate Equipment
Networking
Production Tracking
Sense Process
Networking
Level 3
Resource Management
Networking
Detailed Scheduling
Networking
Manipulate Process
29
Logical Architecture
Maps functional areas and data locations
Independent of technology
30
Centralized
Servers
Desktop
Investigations, Trends,
Level 3
Diagnostics, analysis,
Fault tolerant
ERP Connection
Permanent Database
Operations Control
Area
Operator Control
Production Areas
Data Storage
MES
Batch Execution
Real-time Data
and Buffering
Real-time
Control and
Data Collection
Data Acquisition
Sensors/Actuators
Process/Equipment
Dennis Brandl & Peter Owen
Level 1
31
A Physical Architecture
Defines the IT infrastructure and applications
Vendor capabilities
Networks
Security and network management
32
DataBase
Servers
Historian
Reporter
Level 3
Domain Ctrl
DNS
VLAN
Switch
Network
Management
Router
VLAN
Switch
Configuration
Server
2 way Firewall
Site
Information
Network
Eng Tools
Diag Tools
MES
Server
High Alarm
Low Alarm
Comm. Err.
XML
ERP
Connection
Domain Ctrl
DNS
HMI Server
Historian
Collection
Gateway
OPC
Ethernet
HMI
Viewer
High Alarm
Low Al arm
Comm. Err.
Level 2
Batch
Execution
Network
Management
Router
Ethernet
PLC
DCS
Embedded PC
Packaged Equip
Level 1
33
Conclusions
Linked execution systems deliver results!
Reduced direct costs; increased productivity
Improved traceability; reduced witch hunt expense
Near-theoretical cycle times: customer responsiveness,
reduced WIP inventory
Greater agility: smaller lot sizes, more premium products in
the mix, happier customers, happier shareholders!
34
Status
ISA95.00.01 & ISA.95.00.02 available
IEC/ISO 62264-1 available from IEC & ISO
ISA 95.00.03 in draft
Still under development in the committee
Vendors
Many currently using ISA-95 models in
development and current products
Users
Specifying ISA-95 in their RFPs
Dennis Brandl & Peter Owen
35