ANSI/ISA-95 (IEC/ISO 62264) Industrial Systems Interoperability Operations Management Overview 3 Integrated Manufacturing Systems in the Context of Industry 4.0 Agenda ■ ISA-95 scope ■ ISA-95 (inferred) ontology ■ ISA-95 content ■ ISA-95 usage examples 2 Supply Chain SCOR Model Main SCM processes 3 Supply Chain information flows – ISA-95 scope PLAN Forecasts Planning & Demand Scheduling Demand Aggregation Sales Purchases B2M B2B B2B CRM SRM Schedule Performance Operations Capability definition Capacity (Suppliers) Manufacturing (Customers) SOURCE MAKE DELIVER 4 ISA95 snapshot ■ B2M: Collaboration Business / Execution Communication between execution systems (MES/MOM, DCS, MMS, LIMS, WES, SCADA,…) and business systems (ERP, SCM) Master data management ■ MES/MOM : Functional definition ■ Data and Activity models Description of resources, capability, products, work order requests and reports Definition of operation management activities (MES) ■ Applications: User requirements and functional specification of MES and B2M interfaces Native B2M connectors - MES/ERP (B2MML) Possible basis for developing MES applications and software… 5 Agenda ■ ISA-95 scope ■ ISA-95 (inferred) ontology ■ ISA-95 content ■ ISA-95 usage examples 6 Abstract system model Behaviour (dynammics) Structure (potential) Matter , Action Information Energy Energy, Matter, Information 7 ISA-88/95 industrial system upper ontology Behaviour Structure Operation Process Management ISA-95 Physical Process Management resoures , segments resources resources Physical Process Control Mateiral Human ISA-88 Physical Definitions Equipment Control Capability ISA-88 ISA-95 8 IT systems involved (example) ERP Operations Process Management Physical Process Management MES Physical Process Control DCS/PLC/SCADA Equipment Control 9 Industrial system general process map Customer Market Orders / Demand Forecast Operations Releases Orders management Requirements Manufacturing Processing Capability knowledge Engineering, R&D Processing Sourcing, HR requirements 10 ISA-95 concepts for operations management Operations & Procurement Scheduling Operations Schedule Corresponds to Operations Requests Corresponds to Operations Corresponds to R&D Segments Engineering, Sourcing, HR Product & process knowledge Equipment knowledge Reports Operations Operations Corresponds to Process usage Operations Definition Segments Segments Capability Reports usage Uses Resources Personnel / Equipment / Material 11 Agenda ■ ISA-95 scope ■ ISA-95 (inferred) ontology ■ ISA-95 content ■ ISA-95 usage examples 12 What is ISA-95? Grayed standards are studied in JVI4 course ■ US & International standard “Enterprise - Control System Integration” The ISA95 committee develops the ISA-95 US standard The ISO/IEC JWG5 develops the ISO/IEC62264 internationalstandard US standard INTL Standard Sub Title ANSI/ISA-95.00.01:2010 IEC62264-1:2013 Part 1: Models and Terminology ANSI/ISA-95.00.02:2018 IEC62264-2:2015 Part 2: Object models attributes ANSI/ISA-95.00.03:2013 IEC62264-3:2016 Part 3: Activity Models of Manufacturing Operations Management ANSI/ISA 95.00.04:2018 IEC 62264-4:2015 Part 4: Objects and attributes for manufacturing operations management integration ANSI/ISA-95.00.05: 2018 IEC 62264-5:2016 Part 5: Business to Manufacturing Transactions ANSI/ISA-95.00.06: 2014 IEC PAS 62264-4:2016 Part 6: Messaging Service Model ANSI/ISA-95.00.07:2017 - Part 7: Alias Service Model ANSI/ISA-95.00.08:2020 - Part 8: Manufacturing Operations Management Information Exchange Profiles ISA-TR88.95.01-2008 Using ISA-88 and ISA-95 Together ISA-TR95.01-2018 Master Data Profile Template 13 ISA-95 Scope overview Level 4 Part 1 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Part 2 Level 3 Manufacturing Part 3 PartPart 5/6/7/8 5 Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Part 4 Levels 2,1,0 Batch Continuous Discrete Control Control Control 14 Part 1: Models and Terminology ■ An introduction to the standard ■ Explains its background from PRM (Purdue Reference Model) ■ Only one normative item: physical hierarchy 15 Part 1: planning vs execution processes Manufacturing Planning Configured Make Make Design / Assembled to Order To Stock To Order To Order ISA95 My So Specific Hybrid Continuous Batch Discrete Manufacturing Manufacturing Manufacturing Manufacturing Manufacturing typology Manufacturing Execution 16 Part 1: information categories Manufacturing planing (Operation) (Operation) (Operation) (Operation) definition capability schedule performance information information information information (What must be (What resources (What actual (What actual defined to make are available) job will job was The job) be executed) achieved) Manufacuring Execution 17 Part 1: ISA95 extended physical model Role based equipment hierarchy ENTERPRISE BATCH CONTINUOUS DISCRETE WAREHOUSE SITE PROCESS PROCESS PROCESS (ISA88) AREA WORK PROCESS PRODUCTION PRODUCTION STORAGE CENTER CELL UNIT LINE ZONE STORAGE UNIT UNIT WORK CELL WORK UNIT UNIT EQUIPMENT MODULE CONTROL MODULE 18 Part 2: Object models attributes ■ This standard describes the information models for exchanging information between business and control systems 19 Part 2: Scope Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Levels 2,1,0 Batch Continuous Discrete Control Control Control 20 Part 2: Example - Operations schedule model Operations Operations schedule References performance 0..* 0..* of up Is made up of up Is made Operations Corresponds to 1..* definition 0..* 1..* Operations Contains Is made up of Corresponds to response Operations 0..* 0..* 0..* 0..* Corresponds request Corresponds to 0..* to to Corresponds Work request 1..* 0..* 0..* 0..* of up Is made 0..* Operations of up Is made Is made up of Requested segment 0..* segment to Corresponds 0..* 1..* 0..* response Corresponds 1..* Segment to 0..* 0..* Corresponds to requirement Job order 0..* 0..* Corresponds to a 0..* 1..* of up Is made 0..* Contains Is made up of Process 0..*1 segment 0..1 0..* Specifies Test specification 0..* 0..* 0..* 0..* 0..* 0..* 0..* 0..* 0..* 0..* Segment Personnel Equipment Physical Material parameter requirement requirement asset requirement from Is assembled 0..* 0..* 0..* requirement 0..* 0..* of > values Has of values Has of values Has 0..* 0..* of values Has Contains an element an in to Corresponds element an in to Corresponds element an in to Corresponds an element inan to Corresponds to a Corresponds 0..* 0..* 0..* 0..* Personnel Equipment Physical Material requirement requirement asset requirement property property requirement property property 0..* 0..* 0..* 0..* 0..* 0..* element element in property Maps to a element element in property Maps to a 0..* 0..* element in property Maps to a element element in property Maps to a Contains Contains Contains Contains 0..1 Parameter 1 1 1 specification 1 or process Personnel model Equipment model Material model segment 0..* 0..* Physical asset model 0..* parameter 0..* 21 Part 3: Activity Models of Manufacturing Operations Management ■ This part of ISA-95 defines activity models of manufacturing operations management that enable enterprise system to control system integration. It includes a model of the activities associated with manufacturing operations management, Level 3 functions; an identification of some of the data exchanged between Level 3 activities . Note that the data flows in this part are unusable . They are incomplete and inconsistent with part 2/4 information models ■ This part of the standard provides a documentation structure for Business requirement Functional specifications Software solution marketing 22 Part 3: Scope Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Levels 2,1,0 Batch Continuous Discrete Control Control Control 23 (3) Timing focus MES Main Functional areas Pre-Work Detailed Post-Work Scheduling Reference data Tracking Resource Performance Management Dispatching Analysis Definition Actual Work Management Data collection Execution Management 24 Part 3: A Tri-dimension functional framework Manufacturing Operation Category - Production - Maintenance Operation Manufacturing Operation Core - Quality Tests Processes Functions - Inventory - (Operation) Detailed Scheduling - … - (Operation) Dispatching - (Operation) Execution management - (Operation) Data Collection MES Functional Planning Functional - (Operation) Tracking Requirements Requirements - (Operation) Analyzis - (Operation) Definition Management - (Operation) Resources Management Supporting activities - Management of security - Management of information - Management of configurations - Management of documents - Management of regulatory compliance - Management of incidents and deviations 25 Agenda ■ ISA-95 scope ■ ISA-95 (inferred) ontology ■ ISA-95 content ■ ISA-95 usage examples Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) 26 Context and challenge ■ Central ERP system + hundreds of factories worldwide ■ 3 selected control/MES vendors ■ Difficult decision taken between Let vendors taking care of integration Adopt a company wide interoperability language