1Dennis Brandl
Manufacturing Operations Manufacturing Operations ManagementManagement Manufacturing Operations Manufacturing Operations ManagementManagement
Dennis Brandl Peter Owen
BR&L Consulting Eli Lilly & Co
2Dennis Brandl & Peter Owen
ObjectivesObjectives
• 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
3Dennis Brandl & Peter Owen
Manufacturing in the Supply ChainManufacturing 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
4Dennis Brandl & Peter Owen
Collaborative Manufacturing HelpCollaborative 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
5Dennis Brandl & Peter Owen
Different Points of ViewDifferent 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
• 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
6Dennis Brandl & Peter Owen
Philosophical OrientationPhilosophical Orientation
• Enterprise Management systems:
–How much is my stuff worth?
• Manufacturing Opearations Systems:
–Where is my stuff?
7Dennis Brandl & Peter Owen
ISA 95 Provides DirectionISA 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”
8Dennis Brandl & Peter Owen
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing Operations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
BatchControl
DiscreteControl
ContinuousControl
Level 4
Level 3
Levels2,1,0
ISA95.01 LevelsISA95.01 Levels
Interface addressedin the ISA 95.01 andISA 95.02 standard
Area addressedin the ISA 95.03standard
9Dennis Brandl & Peter Owen
Interface addressedin the ISA 95.01 andISA 95.02 standard
Area addressedin the ISA 95.03standard
Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing Operations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
BatchControl
DiscreteControl
ContinuousControl
Level 4
Level 3
Levels2,1,0
ISA95.01 LevelsISA95.01 Levels
ManufacturingOperations Management
(MES, LIMS, AM, …)
Business LogisticsManagement
(ERP)
10Dennis Brandl
ISA 95 Part 1 and Part 2 ISA 95 Part 1 and Part 2 Exchanged InformationExchanged Information
Information that crosses the boundary between business systems and manufacturing systems
11Dennis Brandl & Peter Owen
Exchanged Information CategoriesExchanged Information Categories
Enterprise InformationPlant Production Scheduling,Operational Management, etc
ManufacturingControl Information
Area Supervision, Production Planning, Reliability, Assurance, etc
ProductDefinition
Information(How to make
a product)
ProductionCapability
Information(What isavailablefor use)
ProductionSchedule
(What tomake and
use)
ProductionPerformance
(What wasmade and
used)
12Dennis Brandl & Peter Owen
4x4 Object Models4x4 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
13Dennis Brandl & Peter Owen
Four Resource Object ModelsFour Resource Object Models
People
Materials
Equipment
Personnel resources managed for production
Equipment resources managed for production
Material resources managed for production
Process Segments
Business view of production processes
14Dennis Brandl & Peter Owen
Capability, Product, Schedule, and Capability, Product, Schedule, and Performance InformationPerformance Information
ProductDefinitions
ProductionSchedule
ProductionPerformance
What is available for use for production
What is needed to make a product
What to make and resources to use
What was made and resources actually used
Product
Time
Capability/Capacity
15Dennis Brandl & Peter Owen
Production ScheduleProduction Schedule
People
Materials
Equipment
Segments
ProductionSchedule
What to makeWhat to make- Priority and/or datesPriority and/or dates- What materials to useWhat materials to use- What equipment to useWhat equipment to use- What personnel to useWhat personnel to use- Production parameters Production parameters (e.g. Color, Options,…) (e.g. Color, Options,…)
Per location (Site, Area, …)Per week, day, shift, order, …
• Production ScheduleProduction Schedule• Production RequestProduction Request• Segment RequestSegment Request
• Expected Produced MaterialExpected Produced Material• Expected Consumed MaterialExpected Consumed Material• Expected PersonnelExpected Personnel• Expected EquipmentExpected Equipment• Production ParametersProduction Parameters• ……
16Dennis Brandl & Peter Owen
Production Performance Production Performance
People
Materials
Equipment
SegmentsProduction
Performance
What was madeWhat was made- What material was What material was actually produced actually produced- What materials were What materials were actually consumed actually consumed- Equipment usedEquipment used- Personnel usedPersonnel used- Production dataProduction data (e.g. Purity, density,…) (e.g. Purity, density,…)
Per location (Site, Area, …)Per location (Site, Area, …)Per shift, hour, Per shift, hour, end of batch, …end of batch, …
• Production PerformanceProduction Performance• Production ResponseProduction Response• Segment ResponseSegment Response
• Produced Material ActualProduced Material Actual• Consumed Material ActualConsumed Material Actual• Personnel ActualPersonnel Actual• Equipment ActualEquipment Actual• Production DataProduction Data• ……
17Dennis Brandl & Peter Owen
XML Standard for B2M ExchangesXML 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
• One schema for each object model• Formal way to exchange information
– www.wbf.org
18Dennis Brandl & Peter Owen
<Material<MaterialLot> <ID> W89W89 </ID> <Description> A lot of materialA lot of material </Description> <MaterialDefinitionID> WXE908WXE908 </MaterialDefinitionID> <Location> Tank 1Tank 1 </Location> <Quantity UnitOfMeasure = "KLKL" > 45004500 </Quantity> <MaterialLotProperty>
<ID> dateTimeProductiondateTimeProduction </ID> <Value> 2001-01-06T00:14:23+11:302001-01-06T00:14:23+11:30 </Value>
</MaterialLotProperty> <MaterialLotProperty>
<ID> Quality StatusQuality Status </ID> <Value> GoodGood </Value>
</MaterialLotProperty></MaterialLot>
</Material>
An XML Example – Material LotAn XML Example – Material Lot
19Dennis Brandl
ISA95 Part 3 ISA95 Part 3 Activity Models of Activity Models of Manufacturing OperationsManufacturing Operations
In Development
Expected Release 2004
20Dennis Brandl & Peter Owen
INVENTORYOPERATIONS
INVENTORYOPERATIONS
MAINTENANCEOPERATIONS
PRODUCTIONOPERATIONS
QUALITYASSURANCEOPERATIONS
Procurement(5.0)
ProductionScheduling
(2.0)
Material andEnergy Control
(4.0)
ProductInventory Control
(7.0)
Product CostAccounting
(8.0)
QualityAssurance
(6.0)
ResearchDevelopment
and Engineering
ProductShipping Admin
(9.0)
OrderProcessing
(1.0)
Marketing& Sales
ProductionControl
(3.0)
MaintenanceManagement
(10.0)
21Dennis Brandl & Peter Owen
ISA 95.03 Manufacturing Operations ISA 95.03 Manufacturing Operations FunctionsFunctions
Productionresource
management
Productioncapability
Analysis
Productiondata
collection
Productionexecution
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Level 2 Process Control
Productdefinition
management
Productdefinition
Equipment and ProcessSpecific Production Rules
Equipment and ProcessSpecific Data
OperationalResponses
OperationalCommands
22Dennis Brandl & Peter Owen
MajorActivities
WithinManufacturing
Operations
QualityOperations
MaintenanceOperations
ProductionOperations
Level 4
Level 3
Level 2
Management of Configuration
Management of Information
Management of Security
Management of Documentation
Management of Compliance
InventoryOperations
Other Enterprise Activities in Other Enterprise Activities in Manufacturing OperationsManufacturing Operations
• Some actives are not specific to manufacturing• ISA-95.03 lists references to standards in these
areas
Activity detailed
Activity not detailedActivity outside scope
23Dennis Brandl & Peter Owen
ImplementationsImplementations
• 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
24Dennis Brandl & Peter Owen
Building Collaborative Manufacturing Building Collaborative Manufacturing SystemsSystems
• Process Used to Develop Solution Architectures– Conceptual Topology– Functional Areas– Standards and Guidelines – Standard Applications– Logical Architecture Design– Physical Architecture Design
25Dennis Brandl & Peter Owen
ISA 95 Control Hierarchy LevelsISA 95 Control Hierarchy Levels
Level 4
Level 0
Level 1
Level 2
Level 3
Business LogisticsPlant Production Scheduling, Shipping,
Receiving, Inventory, etc
ManufacturingOperations Management
Dispatching, Detailed ProductionScheduling, Production Tracking, ...
BatchProduction
Control
DiscreteProduction
Control
ContinuousProduction
Control
ISA – IEC/ISO InterfaceStandards
IEC, OPC, & OMAC InterfaceStandards
ISA FunctionalModel
The production processes
26Dennis Brandl & Peter Owen
Conceptual Topology – IT ViewConceptual 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
27Dennis Brandl & Peter Owen
Conceptual Topology – IT ViewConceptual Topology – IT View
Level 4
Level 1
Level 2
Level 3
I/O, Devices, Sensors
ERP, APO, Logistics Systems
MES, LIMS, WMS, CMM Systems
PLC, DCS, Packaged Systems
Business Process Information Network
Operations Information Network
Automation Network
Discrete & Process Device Communication Networks
HMI, SCADA, Batch Systems
28Dennis Brandl & Peter Owen
Functional AreasFunctional 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 maintaining regulatory compliance.
• Includes such factors as safety, cGMP, and environmental compliance
– The function is critical to plant safety– The function is critical to product quality– The function is critical to plant reliability
29Dennis Brandl & Peter Owen
Level 1
Level 2
Level 3
Business Process Information Network
Operations Information Network
Automation Network
Discrete & Process Device Communication Networks
Functional Areas – From ISA 95 & 88Functional Areas – From ISA 95 & 88
Phase Control
Operator Visibility
Sense Process
Manipulate Process
Sense Events
Manipulate Equipment
On/Off Control Continuous Control
Interlock & Safety Control
Equipment Information Collection
Recipe Control
Product Definition Management
Resource Management
Ne
two
rkin
gN
etw
ork
ing
Ne
two
rkin
g
Operator ControlAlarm Management
Programmed Control
Supervisory Control
Ne
two
rkin
g
Production Dispatching
Production Execution Configuration Management
Production TrackingDetailed Scheduling
Production Analysis
30Dennis Brandl & Peter Owen
Logical ArchitectureLogical 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
31Dennis Brandl & Peter Owen
Level 1
Level 2
Level 3
Logical Architecture – IT ViewLogical Architecture – IT View
Process/EquipmentSensors/Actuators
Controller
Pro
du
cti
on
Are
as
Operations Information Network
Cen
tralize
dS
erv
ers
Deskto
p
Automation Network
Device Connection & /Networks
Business Information Network
Supervisory HMI
Reporting HMIInvestigations, Trends, …
Packaged EquipmentReal-time
Control andData Collection
Real-time Data and Buffering
Fault tolerant Site Data Storage
MES
Data Acquisition
Engineering ToolsDiagnostics, analysis, …
Operator Control
Permanent Database
Operations Control
Reports andAnalysis
Recipe Execution
Area Data Storage
Batch Execution
ERP Connection
32Dennis Brandl & Peter Owen
A Physical ArchitectureA 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– …
33Dennis Brandl & Peter Owen
Physical Architecture – IT ViewPhysical Architecture – IT View
Level 1
Level 2
One Instance PerProcess Cell
Automation Network
Area Operations Information Network
Ethernet
Ethernet
High AlarmLow AlarmComm. Err.HMI
Viewer
Packaged EquipPLC
Level 3Site
InformationNetwork
High AlarmLow AlarmComm. Err.
Eng Tools
Diag Tools
Non operations toolsand views into data
VLANSwitch
ERPConnection
VLANSwitch
2 way Firewall
DNSDomain Ctrl
DCS
XM
L
NetworkNetworkManagementManagement
RouterRouter
NetworkNetworkManagementManagement
RouterRouter
NetworkNetworkManagementManagement
RouterRouter
DNSDomain CtrlHistorian
Reporter
ConfigurationServer
MESServer
BatchExecution
Gateway
HistorianCollection
HMI Server
OPC
DataBaseServers
Embedded PC
34Dennis Brandl & Peter Owen
ConclusionsConclusions
• 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
35Dennis Brandl & Peter Owen
StatusStatus
• 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