Adoption of ISA-95 as the foundation for an

Automation Architecture

Eric C. Cosman
Engineering Services Functional Architect
The Dow Chemical Company

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• Guiding philosophy
. ! • Strategic intent
• Principles
• Architecture in Dow

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 Process Knowledge
!

Advanced, Basic &

Safety Control Strategies

Automated Best
Practices

Defined Migration Paths

Integrated Engineering
Data

Connectivity Through
Standard Networks

Strategic Suppliers

Industry Standards
(Asset Utilization, etc.)
Operational Excellence

Information Access &

Best Automation Solutions

Products & Technology from

Presentation

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Work Process Integration

Business System
Dow Values, Knowledge and Experience in Automation
Integration

Copyright © 2004 The Dow Chemical Company

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Enterprise Domain
Enterprise Domain

Lifecycle
Domain
Our
Current
Focus

Value Chain Domain

Value Chain Domain

Lifecycle Domain
(*) Source: ARC – Used with permission

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Business
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ISA-95 Touches on ALL of these elements

(*) Source: ARC – Used with permission
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Business Planning & Operations

Production Production Production Production
Definition Capability Plan Performance

Collaborative Process Automation System

Production Management

Continuous Batch Logic

Sensors, Actuators and Logical Devices

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• Basis
. ! • Method
• Process
• Areas of Focus

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ISA-95
Levels
Production Production Production Production
3 Definition Capability Plan Information
Manufacturing
.
Operations
. Production Management
2
.
. Continuous Batch Discrete
1 Sensors, Actuators & Logical
. Devices Process
. Control
0

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 feedback loop

Overall
Business
IT Strategy
Scenarios
for Mfg
Business
Business

Stage Gate
Planning
IT Business Business
Process
Strategies Program Solutions Implementation
Plan Plans Plans

Supplier Program
Plan Portfolio
Plan update
Staging
Technology Program &
Plan Approval
Planning

Architecture
feedback loop

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• Operational Excellence
• Views on Integration
• Convergence

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Document &
Services Business eMarket
Procurement Process Non-Strategic
HR Oriented
MRO
& Supplies Indirect
EPC’s
Outsourced Freight Surplus
Process Req ues
t Equipment
ue Req
Rep st ly
ly Rep

External Enterprise Integration Layer

ERP Service Oriented Architecture
CRM
SCM Enterprise Core Applications
Dat

Bus Reporting
Transaction Oriented Architecture
a

Internal Enterprise Integration Layer

Domain Integration Transaction

Oriented Domain Integration

Application Application Application Application

Domain Integration
Build Maintain
Application # Domain Integration
Data Focused Data Focused
Mfg Operations
Application
XML
Application
Data Focused
Process Control
Approved for Release Performance Focused
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Common Information & Processes

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• Basic Process Control is a commodity,

• but the information is not effectively applied
• Enterprise Resource Planning is a given,
• but information flow externally is largely manual
• Advanced manufacturing solutions and supply chain optimization
opportunities:
• Manufacturing Execution Systems
• Logistic Systems
• Advanced Process Control
• Process Driven On-Line Analysis
• Performance Monitoring
• Supply Chain Optimization

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Where is the Value found?

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. * • Internal Challenges
• External Challenges
. ( • Responses Required
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 3

Eric C. Cosman
Engineering Services Functional Architect
The Dow Chemical Company
eccosman@dow.com

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Copyright © 2004 The Dow Chemical Company 51