10 - Isa88 and Isa95

Sistemas Informação IndustrialDesign Patterns do ISA88 e ISA95

Máriode Sousa

[email protected]

Informática Industrial Mário de Sousa

Design Patterns do ISA88 e ISA95

Design Patterns: O que são? ISA88 e ISA95: Overview ISA88 ISA95


Design Patterns: What are they?

TIME


Design Patterns: What are they?

Ferramentas Utilizadas

na fase de Design :– UML

– ...

Design Patterns :– Padrões que se costumam

repetir nos esquemasde architecture design(concepção da arquitectura)

TIME


Design Patterns: O que são?

Ferramentas Utilizadasna fase de Design :

– UML– ...

Design Patterns :– Padrões que se costumam

repetir nos esquemasde architecture design(concepção da arquitectura)

•Em Engenharia de Software, um Design Pattern, é uma solução genérica e reutilizável para um problema recorrente de design.

•Um Design Pattern, não é uma solução terminada que pode ser transformada em código de forma imediata.

•Normalmente é apresentado sobre a forma de um template que tem de ser adaptado a uma situação concreta.


Design Patterns: O que são?

•Gang of Four (GoF) Patterns“Design Patterns: Elements of Reusable Object-Oriented Software”, Erich Gamma, Richard Helm, Ralph Johnson and John Vlissides

•23 classical software design patterns

Inspiração na Arquitectura

“A Pattern Language : Towns, Buildings, Construction”, Christopher Alexander, Sara Ishikawa, Murray Silverstein





ISA88 e ISA95

ISA88 ou IEC 61512-1 Norma que aborda o

controlo de processos do tipo batch (por lotes)

Estabelece uma filosofia para a concepção de arquitectura de alto nível

– define modos de definir equipamentos e procedimentos para os controlar

ISA95 ou IEC 62624 Norma que especifica uma

interface programatica entre o nível de controlo de equipamentos e o de 'gestão' da empresa.

Define conceitos de modelos de informação

– equipamentos, processos, ...


Batch ProcessesBeer, paints, ...


Continuous Production Processes

Waste water Treatment Tratamento de àguas residuais (ETAR)

[www.greeleygov.com] [www.wedotanks.com]


Discrete Production Processes


Processes of type ???????

Production of ropes, cloth, paper mills, ...

[www.tradevv.com]





ISA 88 Overview

International Standard (a.k.a. IEC 61512)

– ANSI/ISA-88.01-1995 Batch Control Part 1 : Models and terminology

– ANSI/ISA-88.00.02-2001 Batch Control Part 2: Data structures and guidelines for languages

– ANSI/ISA-88.00.03-2003 Batch Control Part 3: General and site recipe models and representation

– ANSI/ISA-88.00.04-2006 Batch Control Part 4: Batch Production Records

“The standard consists of models and terminology for structuring the production process and for developing the control of equipment.”

“ISA-88 can be applied in fully automated, semi automated and even in completely manual production processes.”

Result:“It helps industries to produce in a flexible way.”

[http://www.isa-88.com]


ISA88: Main Design Patern

Remember: ISA88 is applied to Batch Processing Main Idea: Separation of Recepy and Equipament Recipy:

– Specifies the actons that must be followed in order to produce a specific product. Does not specify how to execute those actions.(ex.: cake recipy – add flour, oil, sugar, beat ingredients, ...)

Equipament:– Specifies how to execute each action, for each specific machine.

(ex.: oven – gas oven, electric oven, oil oven, ...)


Control Hierarchy

Coordination Control

Procedural Control(em receitas e equipamentos)

Basic Control

Machinery

Specifies the batches to produce, the equipment to use for each batch,And starts the executon of the recipe procedure

Sends commands to the basic control elements in the machinery

IL, ST, LD, FBD

SFC


ISA 88: Equipament HierarchyEnterprise

Site

Area

ProcessCell

ProductionUnit

ProductionLine

StorageZone

Unit Unit Work Cell StorageUnit

Batch production

Continuous Production

Discrete Production

Storage Equipment

Geographical, physical, or logical entity.


ISA95: Hierarquia de EquipamentoEnterprise

Site

Area

ProcessCell

Unit

Produção porLotes

Equipment required for the production of a batch.

Physical equipament and its associated controler , capable of executing one or more actions.

Geographical, physical, or logical entity.


ISA 88 Overview When following ISA 88, we start a project by defining:

– The Physical Model– The Procedures and Recipes

Enterprise

Site

Area

Process Cell

Unit

Equipment Module

Control Module


ISA 88 Overview

Enterprise

Site

Area

Process Cell

Unit

Equipment Module

Control Module

Unit

Process Cell

Equipment Module

When following ISA 88, we start a project by defining:– The Physical Model– The Procedures and Recipes


ISA 88 Overview

Unit

Process Cell

Equipment Module



ISA 88 Overview

Unit Procedure

Operation

Phase

Procedure

Phase

Unit

Process Cell

Equipment Module



ISA 88 Overview

Result:It helps industries to produce in a flexible

way.

But how does this get us closer to... ?


ISA 88 Overview

Mix

Recipe - Light Beer

Add A Add B

Init

Mix

Recipe - Templar's Beer

Add A Add B

Init

Mix

Recipe - Light Beer

Add A Add B

Init

Mix

Recipe - Dark Beer

Add A Add B

Init

We can have a library of procedures (recipes)

that may each be executed on any

Process Cells with sufficient capabilities.

New recipes can be made quickly by re-using existing unit

procedures

Result:It helps industries to produce in a flexible

way.

But how does this get us closer to... ?


ISA 88 Design Patterns

Although ISA 88 does not mandate it, ...it lends itself well to object oriented

design approach.

MAIN IDEA

Decouple recipes from the direct control of equipment.

HOW?

By providing units with similar capabilities with a common interface

(abstraction and encapsulation).

Unit - Blender1

Add AAdd BMix

Unit - Blender2

Add AAdd BMix

NOTE: units with the same interface do not have to be identical!


ISA 88 Design Patterns

We can now allow the same procedure (or recipe) to be executed on either of

the blenders and fermenters...

...and have several recipes simultaneously execute on the same

Process Cell.


ISA 88 Overview

Just two more details... 1st:

ISA 88 defines several 'layers' of

recipes:

•General Recipe

•Site Recipe

•Master Recipe

•Control Recipe

Abby Beer

Abby BeerPorto

Abby BeerSantarém

Abby BeerLine A1

Abby BeerLine A2

Abby BeerLine B1

Lotxyz-42

Lotxyz-42

Lotxyz-42

Lotxyz-42

Lotxyz-42

Lotxyz-42

Lotxyz-42

Lotxyz-314

Lotxyz-42

Lotxyz-42

Lotxyz-42

Lotxyz-271

tem

pl a

tere

cip

es

execu

ted

reci

pes


ISA 88 Overview

Just two more details... 2nd:

ISA 88 allows each Procedure/Recipe to have an internal state:

Executing

Aborting

AbortedStopped

Idle

NOTE: This state machine is independent of the PFC!


Receitas

Receita contem:– Header: informação administrativa

(identificação da receita, identificação do produto, autor, versão, ...)

– Formula: parâmetros de controlo da receita, inputs, e outputs(parâmetros permitem efectuar variantes da mesma receita)

– Procedimento: sequência de operações para executar receita

– Requisitos do Equipamento: Capacidades que o equipamento deve possuir para conseguir produzir a receita

– Outra informação: (ex: informação de segurança, de normas aplicáveis, ...)





EnterpriseResourcePlanning

ManufacturingExecutionSystems

[Dennis Brandl]


ISA95

– ERP systems are only valuable if these have access to current data.

– Many companies still need people to manually exchange and process the information flow between ERP and PCS (Process Control System – e.g., PLC, DCS, ...).

– ISA decided in 1990 to develop a standard for integrating enterprise and control systems

Reduces risk, costs, and errors when doing this integration Allows software from different vendors to communicate and exchange

meaningful data.

ISA 95 is not an automation system, but a method (a way of working, thinking and communicating)


[Dennis Brandl]

PCSlayers


ISA 88[Dennis Brandl]

Informática Industrial Mário de Sousa[Dennis Brandl]


ISA95

ISA 95.00.01– Enterprise – Control System Integration –

Part 1: Models and Terminology


Part 2: Object Attributes


Part 3: Activity Models of Manufacturing Operations Management


ISA95

– Objective: “reduce the cost, risk and errors associated with implementing interfaces

between enterprise and control systems”.

– Advantages: Allows software vendors to support standardised interfaces through which

they may inter-operate with other software

Makes it easier for end-users to define their requirements

Better software integration leads to lowering cost of production processes, and optimization of supply chain management.


ISA 95

Part I– Functional Hierarchy Model

– Equipment Hierarchy Model

– Functional Enterprise-Control Model

– Object Models

– Categories of Information Exchange Model

– Categories of Information Model

“Communicating about a system can be difficult, because different people assign different meanings to general terms. ISA 95 defines words related to integrating enterprise and control systems, and places this terminology within models...”.

“Models describe reality without dealing with every detail. They help us make sense of the world's complexity”.


ISA 95: Functional Hierarchy Model



ERP- processes with time horizons of years, months, weeks, and days - “scope extends beyond the walls of the factory”



MES- activities with time horizons of hours, minutes, and seconds.- scope remains between the factory walls


ISA 95: Equipment Hierarchy ModelEnterprise

Site

Area

ProcessCell

ProductionUnit

ProductionLine

StorageZone

Unit Unit Work Cell StorageUnit

Produção porLotes

ProduçãoContínua

ProduçãoDiscreta

Equipamento de armazenagem

Work Centers

Work Units


ISA 95Functional Enterprise-Control Model

Func

tion

al E

nte r

pri se

Cont

rol M

odel

interface between

levels 3 and 4


[Dennis Brandl]Cate

gor ies

of

I nfo

rma t

ion

Exch

ang e

Mod

e l

ISA 95F


Bibliografia...

Design Patterns for Flexible ManufacturingDennis Brandl, ISA 2007, ISBN-13: 978-1-55617-998-3 (Em especial, os capítulos 1, 2 e 3)

The Road to Integration – A guide to applying the ISA-95 standard in ManufacturingBianca Scholten, ISA 2007, ISBN-13: 978-0-9792343-8-5


Mais Bibliografia...(não disponivel na biblioteca)

Manufacturing Execution Systems - Optimal Design, Planning, and DeploymentEdited by: Meyer, Heiko © 2009 McGraw-Hill

Applying S88 - Batch Control from a User's PerspectiveBy: Parshall, Jim; Lamb, Larry © 2000 ISA



[Dennis Brandl]


Documents

10 - Isa88 and Isa95