Manufacturing Operations

Management

Dennis Brandl Peter Owen

BR&L Consulting Eli Lilly & Co

Dennis Brandl 1
 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 provide 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 and provide visibility of production
• The Manufacturing Operations Management models
are currently being used in the development of
multiple new manufacturing facilities

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 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

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 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

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 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, don’t model
separately
– View from the boardroom
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• 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, don’t
model separately
– View from the workcenter
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 Philosophical Orientation

• Enterprise Management systems:

– How much is my stuff worth?
– How much stuff do I have/need?

• Manufacturing Operations Systems:

– How do I make my stuff?
– Where is my stuff?

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 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”

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 ISA 95 Control Hierarchy Levels

Business Logistics
Level 4 Plant Production Scheduling, Shipping,
Receiving, Inventory, etc

Interface addressed
in the ISA 95.01 and
ISA 95.02 standard
Manufacturing
Area addressed
Level 3 Operations Management in the ISA 95.03
Dispatching, Detailed Production
Scheduling, Production Tracking, ... standard

Level 2
Batch Continuous Discrete
Production Production Production
Control Control Control
Level 1

Level 0 The production processes

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 ISA 95 Control Hierarchy Levels
Business Logistics
Business Logistics
Level 4
Management Plant Production Scheduling, Shipping,
Receiving, Inventory, etc

(ERP) Interface addressed

in the ISA 95.01 and
ISA 95.02 standard
Manufacturing
Level 3
Manufacturing
Operations Management
Area addressed
in the ISA 95.03
Dispatching, Detailed Production
Operations Management standard
Scheduling, Production Tracking, ...

(MES, LIMS, AM, …)

Level 2
Batch Continuous Discrete
Production Production Production
Control Control Control
Level 1

Level 0 The production processes

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 ISA 95 Part 1 and Part 2
Exchanged Information

Information that crosses the boundary between

business systems and manufacturing systems

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 Exchanged Information Categories

Enterprise Information
Plant Production Scheduling,
Operational Management, etc

Production Product
Production Production
Capability Definition
Schedule Performance
InformationInformation (What to (What was
(What is make and made and
(How to make
available use) used)
a product)
for use)

Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc

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 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

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 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

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 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

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 Production Schedule
• Production Schedule
• Production Request
• Segment Request
People • Expected Produced Material
• Expected Consumed Material
• Expected Personnel
• Expected Equipment
• Production Parameters
•…
Equipment
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,…)

Materials
Production
Schedule

Per location (Site, Area, …)

Per week, day,
shift, order, …
Segments

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 Production Performance
• Production Performance
• Production Response
• Segment Response
People • Produced Material Actual
• Consumed Material Actual
• Personnel Actual
• Equipment Actual
• Production Data
•…
Equipment
Materials
Production
Segments
Performance
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What was made
- What material was
actually produced
- What materials were
actually consumed
- Equipment used
- Personnel used
- Production data
(e.g. Purity, density,…)
Per location (Site, Area, …)
Per shift, hour,
end of batch, …
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 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 V2.0
• One schema for each object model
• Formal way to exchange information
– www.wbf.org

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 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>

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 ISA95 Part 3
Activity Models of
Manufacturing Operations
In Development
Expected Release 2004

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 Order
Processing
(1.0) Product Cost Product
Accounting Shipping Admin
(8.0) (9.0)

PRODUCTION
Production
Scheduling
(2.0)
OPERATIONS
INVENTORY
Material and Production OPERATIONS Product
Energy Control Control Inventory Control
(4.0) (3.0) (7.0)
INVENTORY
OPERATIONS QUALITY
ASSURANCE
OPERATIONS
Procurement Quality
MAINTENANCE Assurance
(5.0)
OPERATIONS (6.0)
Marketing
& Sales
Maintenance
Management Research
(10.0) Development
and Engineering

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 ISA 95.03 Manufacturing Operations
Functions
Product Production Production Production
definition capability schedule performance

Detailed
production
scheduling
Production
Production
resource
tracking
management

Production
Analysis
dispatching

Product Production
definition data
management collection

Production
execution

Equipment and Process Operational Operational Equipment and Process

Specific Production Rules Commands Responses Specific Data

Level 2 Process Control

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 Other Enterprise Activities in
Manufacturing Operations
• Production, Maintenance, Inventory, Quality
• Management of information, compliance, security,
documentation, and configurations

Level 4

Level 3 Inventory Management Management

Operations of Information of Configuration
Maintenance Quality Management
Operations Operations of Security
Production Management Management
Operations of Documentation of Compliance
Activity detailed
Level 2 Activity not detailed

Activity outside scope

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 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

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 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

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 ISA 95 Control Hierarchy Levels

Business Logistics ISA – IEC/ISO

Level 4 Plant Production Scheduling, Shipping, Interface
Receiving, Inventory, etc Standards

ISA
Functional
Manufacturing Model

Level 3 Operations Management

Dispatching, Detailed Production IEC, OPC, &
Scheduling, Production Tracking, ... OMAC
Interface
Standards

Level 2
Batch Continuous Discrete
Production Production Production
Control Control Control
Level 1

Level 0 The production processes

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 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

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 Conceptual Topology – IT View
ERP, APO,
Level 4 Logistics Systems

Business Process Information Network

MES, LIMS, WMS,

Level 3 CMM Systems

Operations Information Networks

Level 2 HMI, SCADA,

Batch Systems

Automation Networks

PLC, DCS,
Packaged Systems
Discrete & Process Device Communication Networks

I/O, Devices,
Level 1 Sensors

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 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 plant safety
– The function is critical to product quality
– The function is critical to plant reliability
– The function is critical to maintaining regulatory compliance.
• Includes such factors as safety, cGMP, and environmental
compliance
• Maintaining FDA, EPA, USDA, OSHA, TÜV, EU, EMEA, and
other agency compliance

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 Functional Areas – From ISA 95 & 88

Networking
Business Process Information Network

Detailed Scheduling Resource Management Production Tracking

Level 3 Product Definition Management Production Dispatching

Production Execution Configuration Management Production Analysis

Networking
Operations Information Networks

Level 2 Alarm Management Operator Control Supervisory Control

Networking
Operator Visibility Equipment Information Collection Recipe Control

Automation Networks
Phase Control
On/Off Control Continuous Control

Programmed Control Interlock & Safety Control

Networking
Discrete & Process Device Communication Networks

Sense Events Sense Process

Level 1 Manipulate Equipment Manipulate Process

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 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

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 Logical Architecture – IT View

Desktop
Reports and Reporting HMI Engineering Tools Level 3
Analysis Investigations, Trends, … Diagnostics, analysis, …

Business Information Network

Centralized
Servers

Fault tolerant
Site Data Storage ERP Connection
Permanent Database
Area Data Storage MES
Operations Control
Operations Information Network

Operator Control
Supervisory HMI Recipe Execution
Production Areas

Batch Execution
Real-time Data and Data Acquisition Level 2
Buffering
Automation Network
Real-time
Control and Data
Collection
Controllers Packaged Equipment

Device Connection & /Networks

Sensors/Actuators
Process/Equipment Level 1

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 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
– …

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 Physical Architecture – IT View

XML
One Instance Per Site
DataBase
Servers Historian
Level 3
Domain Ctrl ERP
Reporter DNS Connection
Ethernet

Site
VLAN Information
Switch 2 way Firewall Network
Network Ethernet
Management Configuration Eng Tools
High Alarm
Domain Ctrl
MES
Low Alarm

VLAN
Comm. Err.

Router Diag Tools DNS

Switch Server Server

Non operations tools

Area Operations Information Networks and views into data

Network Ethernet
Management
Router
HMI Server
Historian
High Alarm
Low Alarm

HMI
Comm. Err.
Batch
Execution
WMS
Execution
Level 2
Viewer
Collection
Gateway OPC
One Instance Per
Process Cell
Ethernet Automation Networks
Network
Management
Router
PLC DCS Embedded PC Packaged Equip
Device Networks
Level 1

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 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

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 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
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