Manufacturing Operations Management

Manufacturing Operations
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
The Manufacturing Operations Management models

are currently being used in the development of
multiple new manufacturing facilities
Dennis Brandl & Peter Owen
Manufacturing in the Supply Chain

Make is a significant part of the supply chain and
collaborative manufacturing, but is often the last
element to be actually integrated
Collaboration in Make is usually not a Low Hanging Fruit
But can offer very high ROI for high volume, or high cost
products
However, Business IT and Manufacturing IT

organizations are often at odds as they try to
collaborate
They have different goals and different success criteria
They use the same terms for different elements and different
terms for the same elements
Collaborative Manufacturing Help

Fortunately there are multiple standards in
place to help integrating business systems
with manufacturing systems.
The ISA 95 Enterprise/Control System Integration
standards, also an IEC/ISO standard
XML Schemas standards for collaborative
manufacturing from the World Batch Forum
Will show how they are being applied to the

development of manufacturing systems
roadmap
Different Points of View

Business Systems
Time Horizons
Long-term view
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
View from the boardroom

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
View from the workcenter
Philosophical Orientation
Enterprise Management systems:
How much is my stuff

worth?
Manufacturing Opearations
Systems:
Where is my stuff?
ISA 95 Provides Direction

The ANSI/ISA 95.00.01 Enterprise - Control
System Integration - Part 1: Models and
Terminology
Also Draft International Standard ISO/IEC 62264-1
ANSI/ISA 95.00.02 Enterprise - Control

System Integration - Part 2: Object Attributes
Draft ISA 95.00.03 Enterprise - Control
System Integration - Part 3: Activity Models of
Manufacturing Operations Management
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
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
ISA 95 Part 1 and Part 2

Exchanged Information
Information that crosses the boundary between
business systems and manufacturing systems
Dennis Brandl
10
Exchanged Information Categories

Enterprise Information
Production Product
ProductionProduction
Capability Definition
SchedulePerformance
Information
(What was
Information (What to
(What is
available
for use)
(How to make
a product)
make and
use)
made and
used)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
11
4x4 Object Models

Four categories of resources
Personnel
Equipment
Material (and Energy)
Process Segments
Four Process, Product, & Production Models
Capability & Capacity Definition

Product Definition
Production Schedule
Production Performance
12
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
13
Capability, Product, Schedule, and

Performance Information
What is available for use for production
Product
Time
Capability/Capacity
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
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
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
Per location (Site, Area, )

Per week, day,
shift, order,
15
People
Production Response
Segment Response
Produced Material Actual
Consumed Material Actual
Personnel Actual
Equipment Actual
Production Data
Equipment
What was made

- What material was
actually produced
- What materials were
actually consumed
- Equipment used
- Personnel used
- Production data
(e.g. Purity, density,)
Materials
Segments
Production
Performance
Per location (Site, Area, )

Per shift, hour,
end of batch,
16
XML Standard for B2M Exchanges

The World Batch Forum has developed XML
Schemas that map to the ANSI/ISA-95
models
Defines how to represent the ISA-95
information in XML
Business To Manufacturing Markup Language
B2MML
One schema for each object model

Formal way to exchange information
www.wbf.org
17
An XML Example Material Lot

<Material
<MaterialLot>
<ID> W89 </ID>
<Description> A lot of material </Description>
<MaterialDefinitionID> WXE908 </MaterialDefinitionID>
<Location> Tank 1 </Location>
<Quantity
UnitOfMeasure = "KL" > 4500
</Quantity>
<MaterialLotProperty>
<ID> dateTimeProduction </ID>
<Value> 2001-01-06T00:14:23+11:30 </Value>
</MaterialLotProperty>
<MaterialLotProperty>
<ID> Quality Status </ID>
<Value> Good </Value>
</MaterialLotProperty>
</MaterialLot>
</Material>
18
ISA95 Part 3
Activity Models of
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
ISA 95.03 Manufacturing Operations

Product
Production
Production
Production
Functions
definition
capability
schedule
performance
Detailed
production
scheduling
Production
resource
management
Production
tracking
Production
dispatching
Analysis
Production
data
collection
Product
definition
management
Production
execution
Equipment and Process
Specific Production Rules
Operational
Commands
Operational
Responses
Equipment and Process

Specific Data
Level 2 Process Control
21
Other Enterprise Activities in

Some actives are not specific to manufacturing
ISA-95.03 lists references to standards in these
areas
Level 4
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
23
Building Collaborative Manufacturing

Systems
Process Used to Develop Solution
Architectures
Conceptual Topology
Functional Areas
Standards and Guidelines
Standard Applications
Logical Architecture Design
Physical Architecture Design
24
ISA 95 Control Hierarchy Levels

Level 4
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
ISA IEC/ISO
Interface
Standards
ISA
Functional
Model
IEC, OPC, &

OMAC
Interface
Standards
Batch
Continuous Discrete
Production Production Production
Control
Control
Control
The production processes
25
Conceptual Topology IT View

IT View of the ISA-95 Levels and relationship to
systems and networks
Levels 1-2
Control the process and provide visibility to the process
Electronic records are not embedded in the control layers
(Level 1-2)
Usually some specialized hardware and possibly networks
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
Conceptual Topology IT View

ERP, APO,
Logistics Systems
Level 4
Business Process Information Network
MES, LIMS, WMS,

CMM Systems
Level 3
Operations Information Network
Level 2
HMI, SCADA,
Batch Systems
Automation Network
PLC, DCS,
Packaged Systems
Discrete & Process Device Communication Networks
Level 1
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
The function is critical to plant safety

The function is critical to product quality
The function is critical to plant reliability
28
Business Process Information Network
Production Dispatching
Production Execution Configuration Management
Production Analysis
Operations Information Network
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
Interlock & Safety Control
Discrete & Process Device Communication Networks
Level 1
Sense Events
Manipulate Equipment
Networking
Product Definition Management
Production Tracking
Sense Process
Networking
Level 3
Resource Management
Networking
Detailed Scheduling
Networking
Functional Areas From ISA 95 & 88
Manipulate Process
29
Logical Architecture
Maps functional areas and data locations
Independent of technology
Defines the different layers of the architecture in

terms of data and control
These are mapped to physical networks, servers, and
applications in the physical architecture
Defines what functions are to be performed at each

level, and what data is to be maintained at each level
To result in maintainable and robust systems
To provide a way to manage the life cycle of the production
systems
Provides the structure required to grow and modify the
system without compromising any of the previous
advantages
30
Centralized
Servers
Desktop
Logical Architecture IT View

Reports and
Analysis
Investigations, Trends,
Level 3
Diagnostics, analysis,
Business Information Network
Site Data Storage
Fault tolerant
ERP Connection
Permanent Database
Operations Control
Area
Operator Control
Production Areas
Reporting HMIEngineering Tools
Data Storage
MES
Supervisory HMI Recipe Execution Level 2
Batch Execution
Real-time Data
and Buffering
Real-time
Control and
Data Collection
Data Acquisition
Operations Information Networ

Automation Network
Controller Packaged Equipment
Device Connection & /Network
Sensors/Actuators
Process/Equipment
Level 1
31
A Physical Architecture
Defines the IT infrastructure and applications
Defines networks and network connections

Defines locations of applications
Defines locations of servers
Defines the mapping of applications to servers
Physical architecture depends on the solution

set used:
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
Physical Architecture IT View
ERP
Connection
Domain Ctrl
DNS
Non operations tools

and views into data
Area Operations Information Network

Network
Management
Router
HMI Server
Historian
Collection
Gateway
OPC
Ethernet
HMI
Viewer
High Alarm
Low Al arm
Comm. Err.
Level 2
Batch
Execution
One Instance Per

Process Cell
Automation Network
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!
S95 defines the currency for manufacturing object

and information exchange
Faster project implementation cycles
Flexibility to integrate and realign as corporate structures
change
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
World Batch Forum

Developed XML Schemas for the exchanged
information
Vendors
Many currently using ISA-95 models in
development and current products
Users
Specifying ISA-95 in their RFPs
35

Manufacturing Operations Management

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Manufacturing Operations

The Manufacturing Operations Management models

Dennis Brandl & Peter Owen

Manufacturing in the Supply Chain

However, Business IT and Manufacturing IT

Collaborative Manufacturing Help

Will show how they are being applied to the

Dennis Brandl & Peter Owen

Different Points of View

View from the boardroom

View from the workcenter

How much is my stuff

Dennis Brandl & Peter Owen

ISA 95 Provides Direction

ANSI/ISA 95.00.02 Enterprise - Control

Dennis Brandl & Peter Owen

Dennis Brandl & Peter Owen

ISA 95 Part 1 and Part 2

Exchanged Information Categories

4x4 Object Models

Four Process, Product, & Production Models

Capability & Capacity Definition

Dennis Brandl & Peter Owen

Four Resource Object Models

Equipment resources managed for production

Material resources managed for production

Business view of production processes

Capability, Product, Schedule, and

What is needed to make a product

What to make and resources to use

What was made and resources actually used

Per location (Site, Area, )

What was made

Per location (Site, Area, )

XML Standard for B2M Exchanges

One schema for each object model

An XML Example Material Lot

Dennis Brandl & Peter Owen

Dennis Brandl & Peter Owen

ISA 95.03 Manufacturing Operations

Equipment and Process

Level 2 Process Control

Dennis Brandl & Peter Owen

Other Enterprise Activities in

Dennis Brandl & Peter Owen

Building Collaborative Manufacturing

Dennis Brandl & Peter Owen

ISA 95 Control Hierarchy Levels

IEC, OPC, &

Conceptual Topology IT View

Dennis Brandl & Peter Owen

Conceptual Topology IT View

MES, LIMS, WMS,

The function is critical to plant safety

Dennis Brandl & Peter Owen

Business Process Information Network

Production Execution Configuration Management

Operations Information Network

Interlock & Safety Control

Discrete & Process Device Communication Networks

Dennis Brandl & Peter Owen

Product Definition Management