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Manufacturing Operations Manufacturing Operations ManagementManagement

Manufacturing Operations Manufacturing Operations ManagementManagement

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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

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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

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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

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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

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Philosophical OrientationPhilosophical Orientation

• Enterprise Management systems:

–How much is my stuff worth?

• Manufacturing Operations Systems:

–Where is my stuff?

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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”

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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

Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

Manufacturing Operations & Control

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

Business Logistics Management (ERP)

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Interface addressedin the ISA 95.01 andISA 95.02 standard

Area addressedin the ISA 95.03standard

BatchControl

DiscreteControl

ContinuousControl

Level 4

Level 3

Levels2,1,0

ISA95.01 LevelsISA95.01 Levels

Manufacturing Operations Management (MES)

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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

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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)

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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

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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

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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

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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• ……

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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• ……

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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

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<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

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ISA95 Part 3 ISA95 Part 3 Activity Models of Activity Models of Manufacturing OperationsManufacturing Operations

In Development

Expected Release 2004

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INVENTORYOPERATIONS

INVENTORYOPERATIONS

MAINTENANCEOPERATIONS

PRODUCTIONOPERATIONS

QUALITY

ASSURANCEOPERATIONS

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)

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ISA 95.03 Manufacturing Operations FunctionsISA 95.03 Manufacturing Operations Functions

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

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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

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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

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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

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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

What is the PCIMS ?

PCIMS :Process Control Information Management System

Each plant as an individual process area shall consist of an integrated production control system and the main units of integrated production system consist of :

UCB : Unit Control Building which is the central location for controlling , PCB: process control building

RIB which houses all I/O’s and the controllers

DCS is Distribution Control System

Vendor ,Yokogawa centum CS3000

DCS consist of two main parts :

HIS : Human Interface Station

FCS : Field Control Station

-  it is operator station that is used to monitor and control the process .

FCS is a stand alone unite capable of performing a full data acquisition control ,and all control function are executed there with all I/O’s analog & digital signal.

What is the DCS ?

What is the PESS ?

PESS : Programmable electronic safety system Vendor : ( Triconex )

which is used for emergency shutdown (ESD) function and other equipment tripping function .

What is MMS ?

MMS : Machine Monitoring system Vendor : ( Bentlt Nevada )

Machine Motoring System , the Bently Nevada system is used to monitor the vibration of the shaft and the baring shaft temperature , and to send a signal as hard wire to the shut down system “ PESS” to trip the machine . Which is used in Comp package & critical big Pump..etc.

Like :Tank gauging ,Flow computer for custody meter and Vibration monitoring “ System 1”

Third party Equipment

What is RIB ?

RIB is Remote Instrument Building

The Remote Instrument Building RIB, which will house, the DCS controller as FCS ,HIS ,PESS / PLC controller and their cabinets and all other 3rd party equipment like Tank gauging ,Vibration monitoring , Flow computer , Power supply distribution panel ,Fire and Gas panel and Uninterruptible power supplies (UPS ) . 

- DCS filed control station “ FCS “ Cabinets

- Programmable electronic shut down system “PESS Cabinets

- Machine monitoring system “ MMS Cabinets

- Programmable logic control “PLC” Cabinets

- Other equipment such as Tank Gauging , Custody metering Cabinets

- Air unit

- Fire and gas panel

- All field instruments , wiring signals

- Marshaling panels

-Terminal blocks

-Servers cabinets

What is inside RIB’s

JB

F TA

HIS

TB

FCU

FIO

HIS HIS HIS

Control Room

V-net cable 10 base 5

Optical converter

Fiber optic cable

V-net cable 10 base 2

coaxial cable

RIB

FCSB/N TMR

PLC

Copper multi coreshielded cable

FTA or I/O's cabletwisted multi core ,as TEL cable

One pair copper cable

Serial communication link

Hard wire

YNT

FOPP

YNT

FOPP

V-net converter 10 base 5 to 10 base 10

Black box

To do down loading , Tag equalizing between the HIS,s,Trending , and viewing DCS logic

DCS OPC server

V-net 10 Base 2 cable

Control room YNT

V-Net 10 Base 5 cable

Fiber optic cable

RIB YNT

V-Net cable 10 base 5

FIO

FCS

HIS

RIB Control Room

Fiber optic 100 MP/S

Fiber optic 1GP/S

2

copper

Fiber

PLC, PESS

PESS – PLC OPC server

DCS OPC server

One jacket fiber optic cable consist of 6 orange cable which consist of 4 wire

The total is 12 pare wire inside one jacket

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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

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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