ISA SP95 EnterpriseControl System Integration Project

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ISA SP95Enterprise/Control System Integration
Project

• Dennis Brandl - Sequencia
• www.sequencia.com

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ISA

• The International Society of Measurement and
  Control
• A non-profit organization dedicated to the
  development of the measurement and control
  industry
• More than 47,000 members in more than 110
  countries

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ISA

• Standards
• Recognized by ANSI as a consensus standard
  development organization
• Training
• In the area of measurement and control and
  standards, mostly oriented to manufacturing
• Journals
• InTech Industrial Computing
• Motion Control Control Platforms
• Events
• Trade Shows, Technical Shows, Local chapters

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What is ISA/S95 ?

• ISA standard S95.01 Enterprise - Control System
  Integration - Part 1 Models and Terminology
• SP95 is the committee charged with developing the
  S95 standards
• Will be submitted to IEC or ISO for consideration
  as an international standard

Vendors
General
Users
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SP95 Committee

• Started in October 1996
• First working meeting January 1997
• Who is on it
• Mostly users, Control and MES vendors, with some
  ERP support and participation
• Scope of work
• Defines the interface content between
  manufacturing control functions and other
  enterprise function
• Based upon the Purdue Reference Model for CIM and
  MESA model of manufacturing functions

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Business Drivers

• Business drivers generate the need for
  information to flow between business systems and
  the manufacturing floor
• There must always be a business need for
  information to be exchanged
• There is always some business process that needs
  information from production, or needs to exercise
  control of production
• Requirements for exchanged information are driven
  by the business processes

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Some SP95 Committee Members / Supporters

• Users
• Eli Lilly DuPont Lyondell Chemical (Arco)
• Dow Corning Ben Jerry's Novo Nordisk
• Rohm Haas Sterling
• Vendors
• SAP Marcam InCode
• ABB Rockwell Yokogawa
• Honeywell Groupe Schneider
• Sequencia OSI
• General
• Purdue Fluor Daniels European Batch Forum
• MESA PDXI NAMUR

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• MESA is a not-for-profit trade association
• Founded in 1998 by the leading manufacturing
  execution system software vendors
• Provides a legal forum for competitors to work
  together to expand awareness and use of
  manufacturing technology particularly MES and
  all the related products and services required by
  the modern manufacturing enterprise

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Purdue Reference Model for CIM

• Developed in the late 80's at Purdue University
  by a consortium of user and vendor companies and
  academic personnel.
• Lead by Dr. Theodore Williams (Also past
  president of ISA)
• Contains several models used to describe an
  entire manufacturing company
• Parts of the final report contained in the
  dS95.01 Standard

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Why SP95
No Common Model for Integration
Difficult for Users to Communicate Requirements
S95 Enterprise Control Integration
Integration of Different Vendors is Difficult
Integration Difficult to Achieve
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Why SP95
Part 1 (S95.01)
No Common Model for Integration
Difficult for Users to Communicate Requirements
S95.01 Models
S95.01 Terminology
S95 Enterprise Control Integration
Integration of Different Vendors is Difficult
Integration Difficult to Achieve
dS95.02 t.b.d.
dS95.02 t.b.d.
Part 2 (dS95.02)
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Purpose of the S95.01 Standard

• Improved integration of manufacturing through
  communication by defining
• A common terminology
• A consistent set of models
• Emphasize good practices for integration of
  control systems with other enterprise systems

S95.01
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Scope of S95.01

• The definition of the scope of the manufacturing
  control domain
• A definition of the functions associated with the
  interface between control functions and
  enterprise functions
• A definition of the information which is shared
  between control functions and enterprise functions

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Scope of S95.01

• The figure below is a simplified functional
  hierarchy, illustrating the S95 scope

Level 4
Business Logistics Systems Plant Production
Scheduling and Operational Management
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Scope of S95.01

• Early Question
• How can a single standard cover the broad range
  of manufacturing policies and practices?
• Make to order, make to stock, KANBAN, engineer to
  order, repetitive, continuous, batch,
• The Answer
• Define a model that separates the business
  processes from the production processes
• Define a model that defines the 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
MEASURABLE (e.g. Weight)
Identifying Final Product
Repetitive
Assemble to Order
Engineer to Order
COUNTABLE
Variability of Product
High
Low
HIGH
Amount of information from the business systems
to manufacture systems
LOW
High
Low
Variability of Product
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Scope of SP95
Alternate Logistics Strategies

• S95.01 should not be restricted to specific
  business or manufacturing processes

Make to Stock
Engineer to Order
Configure to Order
Make to Order
S95.01
PDXI NAMUR
S88.01
SME
Batch Manufacturing Models
Discrete Manufacturing Models
Continuous Manufacturing Models
Alternate Manufacturing Strategies
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Different Models For Integration

• Multiple models are used to explain integration
  concepts
• Each focuses on a particular view of the
  integration problem
• The 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
Domain Definitions
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Domain Definitions

• A function is in the control domain if
• The function is critical to maintaining
  regulatory compliance. This includes such factors
  as safety, environmental, and CGMP compliance
• The function is critical to plant reliability
• The function impacts the operation phase of the
  facilitys life
• Why ?
• Answer - where is the responsibility.

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Control Functions

• Based on the MESA Model
• MES Functionalities and MRP to MES Data Flow
  Possibilities - White Paper Number 2 (1994)
• Defines the functions of the MES and Control
  layers in an abstract manner
• Includes touch points to functions outside the
  domain of control
• Document Control
• Labor Management
• Maintenance Management

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Functional Model

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

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Selected Information Of Interest

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

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Categories of Information Identified

• Data flow information is categorized
• Multiple Venn diagrams used to illustrate the
  overlap of information categories

Enterprise Information Plant Production
Scheduling, Operational Management, etc
Product Definition Information (How to make a
product)
Production Capability Information (What
is available)
Production Information (What to make and results)
Manufacturing Control Information Area
Supervision, Production Planning, Reliability,
Assurance, etc
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Information Model

• Detailed definition of objects of interest and
  their relationships
• Object relationships diagramed using UML
  notation, like the segment below
• Defines typical attributes associated with each
  object

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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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Product Definitions

• Product Segment
• Defines segments of production for the product
• Defines the resources and properties of the
  resources required for that segment of production
• Personnel (e.g. 3 operators)
• Equipment (e.g. 1 Milling Machine)
• Material (e.g. 3 Ton Steel Bar)
• Parameters (e.g. Color, Hole Size)
• Product Material
• All materials used in production
• Independent of which segment they are used in

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Production Request

• Production Request
• Made up of production segment requirements
• Reported on by a production response
• Production Segment Requirement
• Always defined, even if only one is needed
• Must correspond to a know product segment
• Defines the specific resources needed for that
  segment of production for the specified
  product(s)
• Personnel (e.g. Jane Smith)
• Equipment (e.g. Cat Cracker 3)
• Material Lot/Sublot
• Parameters (e.g. Color Red)

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Production Response

• A production response is a response to a specific
  production request
• There may be one or more production responses to
  a single request
• The production response defines, per production
  segment
• what was actually produced,
• what was actually consumed
• what equipment was actually used
• what personnel was actually used
• other production data

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Status

• Working Draft 10 (dS95.01-WD10) available on the
  ISA WEB site
• ftp//standardsrtp27709_at_ftp.isa.org
• Should be available for committee ballot after
  the February meeting

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Next Steps

• Decide on a Part 2
• What is needed, by members and by others?
• Possibilities
• Detailed model for Level 3 activities and
  exchanged information
• Detailed model for Level 2-3 exchanged
  information (expanded IEC 61512-2)
• XML definitions for S95.01 information models
• Work with other organizations (e.g. OMG) to
  define implementations for exchange