EnterpriseControl Integration

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ISAThe Instrumentation, Systems, and Automation
Society
Enterprise/Control Integration
Philadelphia Section October 19, 2005 Samuel M.
Herb, PEInvensys Process Systems
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Managing The Enterprise

• Significance of IntegratingEnterprise Resource
  Planning (ERP)withPlant Process Control
  (OCS)in the Real World

Plant Wide MIS/MES/ERP Network
Remote Access
UNIX Operators Stations
Batch Supervisor Workstation
Workstation
PC
X-Terminal
PC
Windows Operators Stations
Controllers
Fieldbus
Remote I/O
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Types of Systems

• ERP
• Enterprise resource planning systems
• MES
• Manufacturing execution systems
• OCS
• Open control systems

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Managing The Enterprise

• Corporations must re-engineer... continuously to
• Respond to market changes
• Respond to technology changes
• Reduce internal fear of change
• Reduce business perturbations
• Manage costs (margins)

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Managing The Enterprise

• Managed, continual change
• Customers see this as positive
• Product growth improvement
• Service growth improvement
• Company growth improvement
• Employees see this additionally as
• Personal growth improvement

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Managing The Enterprise

• Properly directed continual change without
  traumatic bumps needs
• Proper business parameters
• Continually updated information from
• Process control systems
• Factory automation systems
• Continual planning
• Plant personnel acceptance
• Focus on production
• Focus on quality

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Managing The Enterprise

• Requires
• Business Technology
• To become
• Business / Technology
• Expanded workplace which transforms all employees
  into better business people!

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Parts of a Batch Operation
Make a batch of QR6
Execution
The Schedule
The Report
The Equipment
QR6
The Recipe
The Batch
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S88 Functional Models
Process Cell
Unit
EquipmentModule
ControlModule
Elements
Safety Protection
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S95 Simplistic Model
Execution
Instructions (Open valve)
Coordinated
Data (valve opened)
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The S95 Problem
Execution
Instructions (make a batch)
Mismatch
Data (valve opened)
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Control System Must Link to Plant
Enterprise Site Area
Production Information Management
Recipe Management
Production Planning and Scheduling
Instructions (make a batch)
Process Management
Data (Batch Record)
Safety Protection
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Disparate Computing Communities

• Control People understand Plant Floor Complexity
• Enterprise is some cloud..
• Business People understandEnterprise Complexity
• Control system is a little box...

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Information Needs Differ
Board Room
Management Data Needs
Years Quarters Weeks Days Hours Minutes Seco
nds ?Seconds
Corporate Level Plant Level Unit Process Level
Gigabytes Megabytes Kilobytes Analog
Process Data Needs
Process
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Information Capture Requirements
Level
Frequency
Calculation
Years
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Quarters
Corporate
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Material Handling Storage
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Challenge of S95

• Tasks of committee
• Establish common vocabulary
• Find common view of problems
• Build common model
• Define data structures
• Useable for both process discrete
  manufacturing
• Prompt completion, but thorough!

Business Plan
Control System
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Managing The Enterprise

• Business needs
• Planning ERP
• Execution MES
• Control OCS
• Control system contribution
• Right information needed for business plan
• Right timing when needed
• Right context to be properly used
• Right response to planning requirements

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Managing The Enterprise

• IdealDirectbutFlexible

Highly Integrated ERP/MES for Business Planning
Point Click Bridge Between The Two Systems
Complete Access in Place NOW!
Highly Integrated OCS for Production
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Business Planning Vendor
Custom Developed Business Plan
Business Plan Software
Modules

• Role managing the business
• Resource management
• Inventory management
• Recipe management
• Scheduling

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Point Click Mapping
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Software Components
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Link Application Platform Vendor
Modules
Link
Control SystemWorkstation

• Role connectivity
• Point click mapping
• Mapping audit (import/export)
• Automatic event-driven messaging
• Simplification of PP-PI data structures
• Process data upload/recipe download

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Control System Vendor
OCS Workstation

• Role plant control/safety
• Saves time
• Less configuration
• No links to create
• Saves costs
• Less hardware to buy install
• Simple architecture to learn maintain
• Protects investment avoids liabilities

Control
Safety
Control
Process Manufacturing
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OCS Requirements

• More productive results
• Plant operator data available from beginning of
  project ......for faster analysis into business
  plan
• Re-configure control to fit needs ......as
  discovered
• Provides security of equipment, product, and
  personnel...specifically where needed w/o
  penaltyof installation and learning costs

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Managing The Enterprise
BUSINESS NEEDS
Planning
Business planning software
Execution
Point click linking software
Control
Open control system

• Must be easy to use
• Must have consistent openness
• Must have workable domains for both business
  control

gtgt Must work as ONE system!ltlt
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Scope of S95

• Simplified functional hierarchy, illustrates
  S95 scope

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Scope of S95.01

• To Define
• Scope of manufacturing control domain
• Organization of physical assets of manufacturing
  enterprise.
• Functions associated w/ interface between control
  functions and enterprise functions
• Information which is shared between control
  functions and enterprise functions

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Scope of S95.01

• Early Question
• How can one single standard cover broad range of
  manufacturing policies and practices?
• Make to order, make to stock, KANBAN, engineer to
  order, repetitive, continuous, batch,
• The Answer
• Establish model that separates business processes
  from production processes
• Establish a model that defines information, and
  does not force any particular mapping of
  processes to the information

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Range of Manufacturing Types
Continuous
Batch
Mix to Order
Identifying Final Product
Repetitive
Assemble to Order
Engineer to Order
Variability of Product
Amount of information from business systems to
manufacture systems
Variability of Product
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Scope of S95
Alternate Logistics Strategies

• S95 should not be restricted to specific business
  or manufacturing processes

Level 4

• Level 4
• Business Logistics Plant Scheduling
• Level 3
• Area Supervision Production Scheduling
• Levels 2, 1, 0
• Operators, Control Strategies, Sensors, etc.

Level 3
Alternate Manufacturing Strategies
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Models For Integration

• Multiple models are used to explain integration
  concepts
• Each focuses on particular view of integration
  problem
• Models show increasing levels of detail
• Hierarchy Model of Activities
• Data Flow Model of Functions
• Information Categories
• Object Model

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Elements of Models Definitions
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Domain Definitions

• A function is in the control domain if
• Function is needed by operators to do their job
• Function is critical to maintaining regulatory
  compliance.
• Function is critical to plant reliability
• Function impacts operation phase of facilitys
  life (vs. design or construction)
• Domain Determined by where responsibility lies.

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Control Functions

• Based on Manufacturing Execution System
  Association (MESA) Model
• Manufacturing Execution System (MES)
  Functionality
• Material Requirements Planning (MRP) to
  MES Data Flow Possibilities
• Defines functions of MES Control layers
  in an abstract manner
• Includes touch points to functions outside
  domain of control
• Document Control
• Labor Management
• Maintenance Management

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Functional Model

• Defines major functions in a manufacturing
  enterprise, and
• Defines what information is exchanged
• Represented with a data flow model, like
• Why ?
• Provides common modeland set of terms thatcan
  be used to describemajor business operation
  functions

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Functions in Domain(example)
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Production Control Functions(example)
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Selected Information Of Interest

• Information that 'crosses the boundary' is
  identified and detailed

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ISA 95 Part 1 and Part 2
Exchanged Information
Selected Information Of Interest

• Information that must cross the boundary between
  business and manufacturing systems

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Exchanged Information
Enterprise Information Plant Production
Scheduling, Operational Management, etc
Production Capability Information (What
is available for use)
Product Definition Information (How to make a
product)
Production Schedule (What to make and use)
Production Performance (What was made and used)
Manufacturing Control Information Area
Supervision, Production Planning, Reliability,
Assurance, etc
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Information Notation

• Detailed definition of objects of interest and
  their relationships
• Object relationships diagramed
• Unified Modeling language (UML) notation
• Defines typical attributes associated with each
  object

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ISA 95.01 95.02
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Typical Objects

• Production Capability Information
• Production Segments, Personnel, Equipment,
  Material
• Product Definition Information
• Product Segments, Product Material, Personnel
  Specifications, Equipment Specifications,
  Material Specifications
• Product Information
• Production Requests, Production Responses

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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
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Material Definition Example

• Common material information

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Process Segments

• Define the detail of the business view of
  production
• How business processes view production
• May not match the control system partitioning

Pharmaceutical Manufacturing (3 Segments)
Raw Materials
Finished Products
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Capability, Product, Production Information
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Capability Models

• What is available
• Current
• Future
• Per resource, usually a limited resource
• Per segment

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Production Capability

• Production capability
• Theoretical maximum capability and capacity
  available for use in production
• Required information
• For valid scheduling
• For Available-To-Promise business processes
• For supply chain integration
• Made up of measurable capacities
• Current capacity Future capacity
• Committed capacity
• Available capacity
• Unavailable capacity

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Current Future Capabilities(example)
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Production Capability Model(example)
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Product Definition

• Shared information about each product
• References manufacturing instructions
• For Continuous may be flow sheets
• For Batch may be site or master recipes
• For Discrete may be setup or assembly
  instructions
• Defines all materials used by manufacturing
• References the Bill of Materials
• References the Bill of Resources
• May define resources required per segment
• Equipment
• Personnel
• Material

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Per Product Definitions
Material System
Scheduling System
Manufacturing System
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Production Schedule
Per location (Site, Area, ) Per week, day,
shift, order,

• 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,)
• Per Segment

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Production Performance

• What was made
• What material was actually produced
• What materials were actually consumed
• Equipment used
• Personnel used
• Production data (e.g. Purity, density,)
• Per Segment

Per location (Site, Area, ) Per shift, hour,
end of batch,
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Scope S95
95.03
BATCH PROCESS CELL
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ISA Provides Direction

• ANSI/ISA 95.01 Enterprise - Control System
  Integration - Part 1 Models and Terminology
• Also Draft International Standard ISO/IEC 62264-1
• ANSI-ISA 95.02 Enterprise - Control System
  Integration - Part 2 Object Attributes
• ANSI-ISA 95.03 Enterprise - Control System
  Integration - Part 3 Models of Manufacturing
  Operations

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More to S95

• Standard planned continuation of series
  (Parts 4-6)
• To cover object models and attributes of
• manufacturing operations
• management activities
• business-to-manufacturing transactions
• manufacturing operation transactions

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Process Information Flow
ERP Enterprise Resource Planning
Corporate Level
Decision support System
MES Manufacturing Execution System
Plant Level Operational Planning and Decision
Making
RESULTS
OBJECTIVES
Unit Process Level Operational Monitoring and
Control System
OCS Open Control System
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Corporate-wide Systems
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Questions? Comments?
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Glossary of Process/Computer Terms

• http//www.jaomad.com/SamstufGlossary.htm

Selected slides prepared by, jointly with
Dennis Brandl As part of the S95 committee