ISA 95 Overview

Intelligent Production Management Seminar
An ISA95 Overview: Workflow and System Modeling for 21st Century Manufacturing Flexibility
Charlie Gifford Solutions Architect-Lean Performance Mgt. Global Professional Services Business Office (208) 788-5434 Fax: (208) 788-5690 Cell (208) 309-0990 Charlie.Gifford@ge.com
2004 GE Fanuc Automation All rights reserved.
Seminar Overview
Goal of the ISA95 Effort Collaborative Production Management (CPM) Business Drivers ISA95 Direction and Scope of Plant Model Agreement of Control Responsibility Object Model Four categories of resources Four categories of information Part 3: Manufacturing Operations Model Question: What does this mean for actual project implementation? XML - schemas ERP-Proficy connector ISA95 Status
Goals
Understand the market drivers for ISA95 Understand the two points of view for supply chain optimization ISA95 Value and Direction Agreement of Control Responsibility Understand Object Model Proficy is ISA95 Compliant Understand ISA95 Business Value
Ever Had This Happen?

The VP of IT announces that the ERP installation is done, Now the only thing left to do it tie into the plant systems!
PS: The interface solution is trivial and was due yesterday.
To reduce inventory or meet your companys Make-To-Order strategy, you need to run very short schedules (multiple per day) and very fast end of production responses (immediate)!
PS: Dont increase inventory or staff
Goals of the 95 Effort

Integration of business (logistics) systems to manufacturing is hard to do
Different systems, cultures, terminology, timing... Benefits expected from standardization and documentation of best practices
Business Logistics
Manufacturing Operations
Goals of the 95 Effort

Effective operation of manufacturing is hard to do
MES solutions are too related to processing methods and too industryspecific
Business Logistics
Manufacturing Operations
Benefits expected from standardization and documentation of best practices
Manufacturing Process Types Drive Complex System Requirements

Production Types Discrete Manufacturing Batch Processing Continuous Processing Workorder Mgt Categories Engineer-to-Order Make-to-Order Make-to-Stock
Discrete Batch Process
ETO
MTO
MTS
The 9 combinations (or hybrids) of Production Type and Work Order Management each have a different set of business rules processes in their supply chain, enterprise and production base
The Goal of the Industrial Enterprise*

is to make money. Make more money now and in the Future The 3 Basic Metrics:
(T) Throughput :
*Goldratt, The Goal, page 58-62
The rate: the system generates money through sales (I) Inventory (and investments) : The money the system invests in things it intends to sell (all saleable resources: material, equipment) (OE) Operational Expenses : The money the system spends to transform Inventory into Throughput
$$$ Throughput Money coming in
$$$ Inventory
Money tied up inside
$$$ Operational Expenses Money going out
CPM Business Drivers Business Processes and Metrics

Plan Suppliers Supplier
Deliver Source Make Deliver
Customers Customer Source Make Deliver

Source Make Deliver Source
Return
Return
Supplier
Internal or External
Return
Your Company
Return
Customer
Internal or External
SCORs Five Distinct Management Processes
Corporate approach set by optimization view Supply Chain vs. Plant Optimization: 60-80% Liquid Assets are in Supply Chain 60-80% Tangible Assets in your Plants
Supply-Chain Council, 2001 All rights reserved.
CPM Business Drivers Summary: Liquid Asset Optimization

Supply chain optimization Capable to promise Reduced cycle time Asset efficiency Agile Manufacturing Supply Chain & Operator Empowerment Improved Planning
CPM Business Drivers Summary: Tangible Asset Optimization

Increase: Plant Throughput Product quality Rework efficiency Equipment utilization Line uptime Event communication and response
CPM Business Drivers Summary: Tangible Asset Optimization

Decrease: Non-value-add product costs Plant inventory and work-in-process (WIP) Regulatory reporting costs Rework (eliminate) Waste: material and human resources Time-to-volume on a new product introduction (NPI) Time-to-theoretical yield and cycle time on an NPI Line changeover time Maintenance: costs, response time, and downtime Total cost of ownership for IT and controls systems
ISA 95 Provides Direction for Optimization

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 - Part 3: Activity Models of Manufacturing Operations Management Draft ISA 95.00.04 - Part 4: Object Models and Attributes of Manufacturing Operations Management Draft ISA 95.00.05 - Part 5: Business to Manufacturing Transactions
Scope
ENTERPRISE
ISA S88 Standard
SITE
ISA95 Standard
AREA
AREA
AREA
CONTINUOUS PRODUCTION UNIT
BATCH PROCESS CELL
DISCRETE PRODUCTION LINE
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
Scope
ENTERPRISE
ISA S88 Standard
95.01 & 95.02

SITE
95.03
AREA AREA AREA
ISA95 Standard
CONTINUOUS PRODUCTION UNIT
BATCH PROCESS CELL
DISCRETE PRODUCTION LINE
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 Management Levels 2,1,0 (MES, LIMS, AM, )

Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
Manufacturing Operations & Control
Interface addressed in the ISA 95.01 and ISA 95.02 standard Area addressed in the ISA 95.03 standard
Batch Control
Continuous Control
Discrete Control
ISA 95 Part 1 and Part 2 Exchanged Information
Information must efficiently and effectively cross the boundary between business and manufacturing systems
S95 Parts 1, 2 and 3

Part 1 defines: standard terminology and object models scope of the manufacturing control domain functions associated with the interface between control functions and enterprise functions information that is shared between control functions and enterprise functions attributes for all objects that are defined in Part 1. The objects and attributes are used for exchange of information between different systems and used as the basis for relational databases. the functions and activities at level 3 (Production Management layer)
Part 2 defines:
Part 3 defines:
ISA 95 Models and Definitions

Domain Definitions Functions in Domains Functions of Interest
Information Definitions
Categories of Information
Information Flows of Interest
S95 Functional Enterprise-Control Model

Order Processing (1.0)
Product Cost Accounting (8.0)
Product Shipping Admin (9.0)
Production Scheduling (2.0) Production Control (3.0)
Product Inventory Control(7.0)
Material and Energy Control (4.0)
ISA S95 Part 1&2
Quality Assurance (6.0)
Procurement (5.0)
Maintenance Management (10.0)
Research Development & Engineering
Marketing & Sales
Identified Information Categories (Flows)

Enterprise Information
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
Agreements on the Control Responsibility

Drawing the line between the Level 3 and the Level 4 functions A function is in the control domain if:
The function is critical to:
> maintaining regulatory compliance.
Includes such factors as safety, cGMP, and environmental compliance
> plant safety > product quality > plant reliability
Why ?
Where is the responsibility ? Who has the responsibility ? Where are firewalls needed (policy and technology) ?
dS95.03 Production Control Functions Where is the Line of Responsibly?

Product definition Production capability Production schedule Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis Production performance
Level 2 Process Control
Section 14: Logistics vs. Operations?
Determine Lines of Responsibility vs. Technical Integration between Level 3 and 4

The functions critical to Level 3: Product quality, Plant safety, Plant reliability and Maintaining regulatory compliance
Maintenance
Maintenance definitions Maintenance capability Maintenance request Maintenance response Product definition
Production
Production capability Production schedule Production performance Quality definitions Quality test capability Detailed production scheduling
Quality
Quality test request Quality test response Inventory definitions Detailed quality test scheduling
Inventory
Inventory capability Inventory request Inventory response Detailed inventory scheduling
T R
Maintenance resource management
Detailed maintenance scheduling
Maintenance tracking
Production resource management
Production tracking
Quality test resource management Production performance analysis
Quality test tracking
Inventory resource management
Inventory tracking
Maintenance dispatching
Maintenance analysis
Production dispatching
Quality test dispatching
Quality analysis Inventory definition management
Inventory dispatching
Inventory analysis
Maintenance definition management
Maintenance data collection
Product definition management
Production data collection
Quality definition management
Quality test data collection
Inventory data collection
Maintenance execution
Production execution
Quality test execution
Inventory execution
Level 2
4x4 Object Model Describes Data Flows

Four categories of resources
Personnel Equipment Material (and Energy) Process Segments
Four categories of information

Capability & Capacity Definition Product Definition Production Schedule Production Performance
S95 Functional Enterprise-Control Model

Order Processing (1.0) Product Cost Accounting (8.0) Product Shipping Admin (9.0)
Production Scheduling (2.0) Production Control (3.0)
Product Inventory Control(7.0)
ISA S95 Part 1&2
Quality Assurance (6.0)
Procurement (5.0)
Maintenance Management (10.0)
Research Development & Engineering
Marketing & Sales
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org 2004 GE Fanuc Automation All rights reserved.
Four Resource Object Models

Personnel resources managed for production People Equipment resources managed for production Equipment Material and Energy resources managed for production Business view of production processes Process Segments
Materials
Persons and Personnel Classes with Required Properties

The picture below represents person and personnel class information
Supervisor Professional Engineer Laborer Operator Pump Mechanic Draftsman
Qualification Test
Sally Jones- ID#12344
Joe Smith - ID#12345
Qualification Test Results
Standard Terminology For Equipment Classification

Level 4 activities typically deal with these objects
ENTERPRISE SITE
Level 3 activities typically deal with these objects
AREA
PROCESS CELL UNIT
PRODUCTION UNIT
PRODUCTION LINE WORK CELL
STORAGE AREA STORAGE UNIT
Lower level Lower level Lower level Lower level equipment used equipment used equipment used equipment used in continuous in repetitive or in inventory in batch operations operations discrete operations operations
Material Classes, Definition, Lots, Sublots, and Properties

Standard terminology for defining material information
Material Class Material Definition HCl 50% HCl Acid
l ria e at ss M la C l ria n e at itio M in ef D
Lot HCL-50-100019
Sublot HCL-50-100019 Barrel 15
pH Density
Color Purity
QA Test Results
pH 1.0
QA Test Location Specification

Density Color Purity 1.05 Straw 99.5%
Process Segments
The business view of production
Raw Materials Finished Products
Pharmaceutical Manufacturing
(3 Segments) Make Active Ingredient Make Pills Package Doses
Inventory tracked for Active Ingredient
Inventory tracked for Pills
Inventory tracked for Pill Packs
Know throughput, Know throughput, resources and time to resources and time to make Active Ingredient make Pills
Know throughput, resources and time to make Pill Packs
Capability, Product, Schedule, and Performance Information

What is available for use for production
Product
Capability/Capacity
Time
Product Definitions
What is needed to make a product
What to make and resources to use

Production Schedule
What was made and resources actually used

Production Performance
Production Capability Models

People
Product
Time
Capabilities
Equipment
Materials
What is available - Currently - In the future - Per resource - Per segment of production - What is available - What is unattainable - What is committed
Segments
Production Capability & Capacity

Current Production Capacity
Production Capacity
Capacity
Unattainable Capacity Available Capacity Committed Capacity
Time
Current Capacities
Product Definition
Shared information about each product between Level 3 and 4
References manufacturing instructions
> For Continuous may be flow sheets > For Batch may be site or master recipes > For Discrete may be setup or assembly instructions
Defines all materials used by manufacturing
Product Definition
References the Bill of Materials References the Bill of Resources Defines resources required per segment
Equipment Personnel Material
Per Product Definitions

Scheduling System
Bill Of Resources e.g. 10 Speed Bicycle
ll O es Bi urc so Re f
Product Definition
Product Segments
Material System
Bill Of Materials e.g. 10 Speed Bicycle
f ll O als i Bi er at M
Frame Final Assembly Assembly Frame Type Seat Height
Paint
Production Rules e.g. 10 Speed Bicycle ly

b em ns ss ctio A ru st In
Color
Manufacturing System
Manufacturing Bill Frame : 1 Wheels : 2 Chain : 1 Seat : 1 Handlebars :1 Brake Pads : 4 ...
Production Schedule
People
Production Schedule What to make Production Request - Priority and/or dates Segment Request Expected Produced - What to use: -Materials Material -Equipment Expected Consumed -personnel Material - Production parameters Expected Personnel (e.g. Color, Options,) Expected Equipment Production Parameters
Equipment
Materials
Production Schedule
Per location (Site, Area, ) Per week, day, shift, order,
Segments
People
Production Performance Production Response Segment Response Produced Material Actual Consumed Material Actual Personnel Actual Equipment Actual Production Data
What was made - What material was actually produced - What materials were actually consumed - Equipment used - Personnel used - Production data (e.g. Purity, density,)
Equipment
Materials
Segments
Per location (Site, Area, ) Per shift, hour, end of batch,
ISA95 Part 3: Activity Models of Manufacturing Operations

Order Processing (1.0) Product Cost Accounting (8.0) Product Shipping Admin (9.0) Production Scheduling (2.0)
PRODUCTION OPERATIONS
Production Control (3.0)
INVENTORY OPERATIONS

INVENTORY OPERATIONS
Product Inventory Control (7.0)
QUALITY ASSURANCE OPERATIONS MAINTENANCE OPERATIONS

Maintenance Management (10.0) Quality Assurance (6.0) Marketing & Sales Research Development and Engineering
Procurement (5.0)
In Development Draft 17 Available
d95.03 Manufacturing Operations Functions

Product definition Production capability Production schedule Detailed production scheduling Production resource management Production dispatching Product definition management Production execution
Equipment and Process Specific Production Rules Operational Commands Operational Responses Equipment and Process Specific Data
Production performance
Production tracking Analysis Production data collection
Level 2 Process Control
Business plan* (APICS terminology)

(Per Product Line, Per Time Very Long Time Horizon)
Demand plan* (APICS terminology)

(Per Product, Per Time Long Time Horizon)
1.1 Production Forecasting Activity (ISA-95.01 )
Production Schedule Flow
Production plan* (APICS terminology)

(Per Product, Per Time - Long Time Horizon)
2.4 Production scheduling activity (ISA-95.01)
Production schedule (Master production schedule - APICS terminology)

(Per Site/Area, Per Product, Per Time Medium Time Horizon)
Detailed production scheduling activity (ISA-95.03)
Detailed production schedule
(Per Workcenter, Per Product/Intermediate, Per Time Short Time Horizon)
Production dispatching activity (ISA-95.03)
Production Dispatch list

* Not in the scope of this standard
(Per Workcenter or Workcenter element, Per produced item, Per Time Very Short Time Horizon)
Other Enterprise Activities in Manufacturing Operations

Some actives are not specific to manufacturing ISA-95.03 lists references to standards in these areas
Level 4
Inventory Operations Maintenance Operations Production Operations Management of Information Quality Operations Management of Configuration
Major Activities Within Manufacturing Operations
Level 3
Management of Security Management of Compliance
Management of Documentation
Activity detailed Activity not detailed Activity outside scope
Level 2
Question: What does this mean for actual project implementation?

Answer: XML Schemas: Common Language and Common Protocol between Levels 3 and 4
B2MML - Business to Manufacturing Markup Language

XML-based implementation of ISA95 standard developed by the volunteer effort of the WBF's XML Working Group Provides a set of XML schemas based upon the ANSI/ISA 95 family of standards. The schemas were written using the World Wide Web Consortiums XML Schema language (XSD) Used to integrate ERP and supply chain management systems with manufacturing systems Formal way to document information and agreements NOTE: Does not define TRANSACTIONS, just the data to be used inside other transaction systems (e.g. OAG)
B2MML: Schemas
Common Schema Equipment Schema Material Schema Personnel Schema Process Segment Schema Product Definition Production Capability Production Performance Production Schedule Maintenance Schema
Why XML ?
Openness Simplicity Self-describing Interoperability Structure Extensibility Platform independency X-Path Query Language Self-documenting Fully Extensible
ERP - Proficy Connector

ERP System
XML Input Schemas B2MML
Equipment Maintenance Material Process Segment Product Definition Production Capability Production Performance Production Schedule
S95 Connector
XML Standard Schema Transaction Table compatible

Proficy Transaction Table
S95 Business Values

Easier Level 3 product comparison, selection, and replacement using consistent models and language across all industries Enhanced protection of end users intellectual property through consistent supplier product functional partitioning Easier flow of information from consistent messaging between business and production systems Faster implementation of integration projects by enabling industry-wide standards using current technologies LARGE Reduction implementation and maintenance costs for enterprise integration through the use of single interface schema
Status
ISA95.00.01 & ISA.95.00.02 available IEC/ISO 62264-1 available from IEC & ISO ISA 95.00.03 /.04/.05 in draft World Batch Forum Vendors Users
Still under development in the committee Developed XML Schemas for the exchanged information Many currently using ISA-95 models in development and current products Specifying ISA-95 in their RFPs

ISA 95 Overview

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Intelligent Production Management Seminar

2004 GE Fanuc Automation All rights reserved.

2004 GE Fanuc Automation All rights reserved.

2004 GE Fanuc Automation All rights reserved.

Ever Had This Happen?

Goals of the 95 Effort

2004 GE Fanuc Automation All rights reserved.

Goals of the 95 Effort

Benefits expected from standardization and documentation of best practices

2004 GE Fanuc Automation All rights reserved.

Manufacturing Process Types Drive Complex System Requirements

The Goal of the Industrial Enterprise*

$$$ Operational Expenses Money going out

2004 GE Fanuc Automation All rights reserved.

CPM Business Drivers Business Processes and Metrics

Customers Customer Source Make Deliver

SCORs Five Distinct Management Processes

Supply-Chain Council, 2001 All rights reserved.

CPM Business Drivers Summary: Liquid Asset Optimization

2004 GE Fanuc Automation All rights reserved.

CPM Business Drivers Summary: Tangible Asset Optimization

2004 GE Fanuc Automation All rights reserved.

CPM Business Drivers Summary: Tangible Asset Optimization

ISA 95 Provides Direction for Optimization

2004 GE Fanuc Automation All rights reserved.

ISA S88 Standard

CONTINUOUS PRODUCTION UNIT

BATCH PROCESS CELL

DISCRETE PRODUCTION LINE

From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org

2004 GE Fanuc Automation All rights reserved.

ISA S88 Standard

95.01 & 95.02

CONTINUOUS PRODUCTION UNIT

BATCH PROCESS CELL

DISCRETE PRODUCTION LINE

2004 GE Fanuc Automation All rights reserved.

Level 3 Manufacturing Operations & Control

2004 GE Fanuc Automation All rights reserved.

Business Logistics Business Planning & Logistics Management (ERP) Level 3

Manufacturing Operations Management Levels 2,1,0 (MES, LIMS, AM, )

Manufacturing Operations & Control

2004 GE Fanuc Automation All rights reserved.

ISA 95 Part 1 and Part 2 Exchanged Information

S95 Parts 1, 2 and 3

2004 GE Fanuc Automation All rights reserved.

ISA 95 Models and Definitions

Information Flows of Interest

S95 Functional Enterprise-Control Model

Order Processing (1.0)

Product Cost Accounting (8.0)

Product Shipping Admin (9.0)

Production Scheduling (2.0) Production Control (3.0)

Product Inventory Control(7.0)

Material and Energy Control (4.0)

ISA S95 Part 1&2

Quality Assurance (6.0)

Maintenance Management (10.0)

Research Development & Engineering

Marketing & Sales

2004 GE Fanuc Automation All rights reserved.

Identified Information Categories (Flows)

Area Supervision, Production Planning, Reliability, Assurance, etc