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Management
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 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
• Manufacturing Opearations
Systems:
–Where is my stuff?
Interface addressed
in the ISA 95.01 and
Level 3 ISA 95.02 standard
Manufacturing Area addressed
Operations & Control in the ISA 95.03
Dispatching Production, Detailed Production standard
Scheduling, Reliability Assurance, ...
Levels
2,1,0
Batch Continuous Discrete
Control Control Control
(ERP)
Interface addressed
in the ISA 95.01 and
Level 3 ISA 95.02 standard
Manufacturing Area addressed
Operations Management
Scheduling, Reliability Assurance, ...
Levels
(MES, LIMS, AM, …)
2,1,0
Batch Continuous Discrete
Control Control Control
Dennis Brandl 10
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
People
Equipment
Process Segments
Production
Performance
Materials
Production
Schedule
Materials
Dennis Brandl 19
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
Detailed
production
scheduling
Production
Production
resource
tracking
management
Production
Analysis
dispatching
Product Production
definition data
management collection
Production
execution
Level 2
Activity detailed
ISA
Functional
Manufacturing Model
Level 2
Batch Continuous Discrete
Production Production Production
Control Control Control
Level 1
Automation Network
PLC, DCS,
Packaged Systems
Discrete & Process Device Communication Networks
Networking
Business Process Information Network
Detailed Scheduling Resource Management Production Tracking
Networking
Production Execution Configuration Management Production Analysis
Networking
Operator Visibility Equipment Information Collection
Automation Network
Phase Control
On/Off Control Continuous Control
Networking
Discrete & Process Device Communication Networks
Desktop
Reports and Reporting HMI Engineering Tools Level 3
Analysis Investigations, Trends, … Diagnostics, analysis, …
Permanent Database
Operations Control Area Data Storage MES
XML
DataBase
Servers Historian
Level 3
Domain Ctrl ERP
Reporter DNS Site Connection
VLAN Information
Switch 2 way Firewall Network
Network Eng Tools
Management Configuration
High Alarm
VLAN
Comm. Err.
Router DNS
Switch Server Server
Network Ethernet
Management
Router
HMI Server
Historian HMI
High Alarm
Low Alarm
Comm. Err. Batch Level 2
Viewer Execution
Collection
Gateway OPC
One Instance Per
Process Cell
Automation Network
Network Ethernet
Management
Router
PLC DCS Embedded PC Packaged Equip Level 1