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Jean Vieille 2010 AttributionNonCommercialShareAlike Creative Commons 3.0 Unported . Paternité Pas d'Utilisation Commerciale Partage des Conditions Initiales à l'Identique

Work: ISA8895 Implementation Section: Overview Chapter: Modelling
Language: English Version: V2 - 10/2010

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Intelligent Industrial Systems

1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pp

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Agenda


ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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Automation challenge
Ideal Automation Flexibility ISA-88

« manual Control »

Capability

Darin Flemming Lou Pillai

« Classical » Automation
Intelligent Industrial Systems

Complexity 3

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ISA88 standard


US and International "Batch Control" standard The ISA88 committee develops the US ANSI standard The IEC65A WG11 develops the IEC international standard
US standard ANSI/ISA-88.00.01: 2010 ANSI/ISA-88.00.02: 2001 ANSI/ISA-88.00.03: 2003 ANSI/ISA-88.00.04: 2006 ISA Draft88.00.05 INTL Standard IEC 61512-1: 1997 IEC 61512-2: 2001 IEC 61512-3: 2008 IEC 61512-4: 2009 Sub Title Part 1: Models and Terminology" Part 2: Data structures and guidelines for languages Part 3: General and Site Recipe - Models and Representation Part 4: Batch Production Records Part 5: Implementation Models & Terminology for Modular Equipment Control

Intelligent Industrial Systems

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ISA88 snapshot












Object Design of automation applications Ø Reuse, Knowledge Management, Robustness Flexible Design of automation applications - No programming required for Ø Modification of recipes, making different products with the same facility Ø Using alternate equipment for the same production step Ø Sequencing production runs for different products Interoperability Ø Assembling software components from different origins Product Industrialization Ø Neutral specification of product physico-chemical transformations Ø Conversion of this specification into operating procedure for target facilities Production Information Ø Data structures for production information history Ø Includes several ISA-95 models Applications Ø Initially designed for Batch processes, but applicable to any type of process Ø Functional specification, batch managers, historians, PDM/PLM
Intelligent Industrial Systems

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ISA88 Adoption








Automation Functional Engineering Good Practices Ø Largely applied worldwide, proven benefits Best known in process industries Ø Less in other domains... All automation vendors offer solutions Ø Generally limited to the support of recipes (authoring, execution, reporting) Ø Sometime at the equipment control level Applies more and more to all types of production Ø No equivalent standards for discrete and continuous processes... Ø Adapt easily Ø Most benefits with globalized application: all types of processes, all locations

Intelligent Industrial Systems

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Agenda


ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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ISA95 snapshot






B2M: Collaboration Business / Execution Ø Communication between execution systems (MES/MOM, DCS, MMS, LIMS, WES, SCADA,...) and business systems (ERP, SCM) Ø Master data management MES/MOM : Functional definition Data and Activity models Ø Description of resources, capability, products, work order requests and reports Ø Definition of operation management activities (MES) Applications: Ø User requirements and functional specification of MES and B2M interfaces Ø Native B2M connectors - MES/ERP (B2MML) Ø Possible basis for developing MES applications and software...

Intelligent Industrial Systems

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What is ISA95?


US & International standard "Enterprise - Control System Integration" The ISA95 committee develops the ISA-95 standards The ISO/IEC JWG5 develops the international standard
INTL Standard IEC/ISO 62264-1: 2003 IEC/ISO 62264-2: 2004 IEC/ISO 62264-3: 2007 IEC/ISO 62264-5: 2010 (APUB) Sub Title Part 1: Models and Terminology" Part 2: Data Structures and Attributes" Part 3: Activity Models of Manufacturing Operations Management (Part 4: Object Models and Attributes of Manufacturing Operations Management) Part 5: Business to Manufacturing Transactions

US standard ANSI/ISA-95.00.01: 2010 ANSI/ISA-95.00.02: 2010 ANSI/ISA-95.00.03: 2005 ISA draft 95.00.04 ASNI/ISA-95.00.05: 2007

Intelligent Industrial Systems

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Benefits and adoption of ISA95




Benefits: Ø Direct : Cost and risk reduction of MES and B2M projects Ø Indirect : § Improvement of operational performance : CTP, agile manufacturing, planning feedback, error reduction § Dynamization of IT/Business alignment Adoption: Ø Most automation / MES vendors claim their adhesion to ISA95 Ø ERP vendors ignore it § Noticeable exception: SAP since 2004 Ø B2MML becomes the de facto standard for B2M information exchange

Intelligent Industrial Systems

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Agenda


ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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CCM global IIPS life cycle
IIPS : Industrial Information Processing Systems Manage Strategy Guidance

Master Planning User Requirement s Execute IIPS Construction IIPS Support Maintenance IIPS Deployment IIPS Operation Use

Industrial Architecture

Information Technology
Intelligent Industrial Systems

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CCM global IIPS life cycle

Information Service Definition Industrial Architecture User Requirement s

IT Resource Development IIPS Construction IIPS Support Maintenance IIPS Deployment IIPS Operation

Run-time Information Processing
Intelligent Industrial Systems

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ISA95 like IIPS life cycle
Run-time Information Processing Information Service Requests Information Services Requests

Information Services (BP)

Information Services (Task)

Information Services (implemented) Resources HW, SW, DWH

Information Services Capability

Information Service Definition
Intelligent Industrial Systems

IT Resource Development 14

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Agenda


ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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Industrial Architecture Models Purpose






Scope Ø The entire industrial facility ­ the Production sub-system within the Enterprise system Ø Spatio-temporal description (structures and interactions) of this subsystem Ø The information reality that tights Energy and Matter together Ongoing maintenance Ø This module only presents models for describing the facility Ø However, the facility is ever changing. § The Industrial Architecture Processes (IAP) integrates IAM within the global enterprise strategy definition and fulfillment process IAM provides the framework Ø For capturing and managing knowledge Ø For mastering IIPS development planning
Intelligent Industrial Systems

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Industrial Architecture Dimensions

Product Asset Management

Physical Asset Management

Operations Process Management

Inventory Asset Management

Physical Process Management

Physical Process Control

ISA88

Equipment Control

ISA88 + ISA95 TOGAF ITIL
Intelligent Industrial Systems

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IT Asset Management

ISA95

Human Asset Management

IIPS Scope in Industrial Architecture framework
Business Information Processing Systems
Marketing, R&D, HR, Engineering, Sales, Purchasing, Finance/accounting, planning

Industrial Information Processing Systems ISA95 ISA 88
Operations Process Management Resource & Definitions Management Scheduling, Dispatching, Analysis, Performance, Tracking, Reporting

Production Inventory, Logistics Quality Maintenance Tooling ... Risk & Safety Information Configurations Documentation Regulation Incidents & Deviations ...

Physical Process Management Work Segments & Resources Physical Process Control Operating procedures, Routings, Recipes Equipment Control Basic, Procedural, Coordination Control
Intelligent Industrial Systems

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Common IT systems involved

ERP

Operations Process Management

Physical Process Management

MES

Physical Process Control

AUTOMATION

Equipment Control

Intelligent Industrial Systems

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Agenda


ISA-88 snapshot ISA-95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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ISA88 Process model (Processing Requirement)

Process

A Process is made up of an ordered set of one or more Process Stages

Process Stage

A Process Stage is made up of an ordered set of one or more Process Operations

Process Operation

A Process Operation is made up of an ordered set of one or more Process Actions

Process Action
Intelligent Industrial Systems

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Product Inventory Asset Physical Asset Human Asset Asset IT Asset

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Resource models (Structural description)




The resource asset models (Personnel, Equipment, and Material) are based on the ISA-95 breakdown. All these resources share a similar pattern. Equipment and Material are indeed the same entity: A "machine" can be: Ø A "Physical Asset" for the company that makes products with it, Ø An "Inventory Asset" for the company that makes them (finish product) or sell / distributes it

Intelligent Industrial Systems

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Product Inventory Asset Physical Asset Human Asset Asset IT Asset

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ISA95 Material Model
Is assembled from Is assembled from Is assembled from Is assembled from

0..n

0..n Defines a grouping 0..n

0..n 0..n 1..1 Defined by

0..n Made up of

0..n

0..n

Material Class
Has properties of

0..n

Material Definition
Has properties of

Material Lot

0..n

Material Sublot
0..n

Is tested by a >

Is tested by a > 0..n 0..n 0..n

Is tested by a > 0..n

Has values for

Has values for

May be made up of sublots

Material Test Specification
Defines a procedure for obtaining a 0..n Records the execution of

Is tested by a > 0..n

0..n Is tested by a > 0..n

QA Test Result

0..n

0..n

0..n < may contain nested

0..n < may contain nested

0..n < may contain nested

Intelligent Industrial Systems

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Product Inventory Asset Physical Asset Human Asset Asset IT Asset

Material Class Property

May map to

Material Definition Property

0..n Maps to

0..n

Material Lot Property

0..n

23

ISA95 extended physical model (Actual Facility layout)
ENTERPRISE SITE AREA WORK CENTER PROCESS CELL PRODUCTION UNIT PRODUCTION LINE STORAGE ZONE BATCH PROCESS (ISA88) CONTINUOUS PROCESS DISCRETE PROCESS WAREHOUSE

WORK UNIT

UNIT

UNIT

WORK CELL

STORAGE UNIT

CONTROL MODULE

Intelligent Industrial Systems

1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pp

Product Inventory Asset Physical Asset Human Asset Asset IT Asset

EQUIPMENT MODULE

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ISA95 Equipment Model
< May be made up of 0..n 0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n

Equipment Class
Has properties of >

Equipment
Has values for >

Equipment Capability Test Specification
0..n Is tested by an > Defines a procedure for obtaining an > 0..n Maps to 0..n 0..n < Records the execution of

Equipment Capability Test Result

0..n < may contain nested
Intelligent Industrial Systems

0..n < may contain nested

1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pp

Product Inventory Asset Physical Asset Human Asset Asset IT Asset

Equipment Class Property

0..n

0..n

Equipment Property

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ISA95 Personnel Model
Personnel Class
Has properties of > 0..n 0..n Is tested by a > 0..n < Defined by 0..n Is tested by a > 0..n Has values for >

Person

0..n

Qualification Test Specification
0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n

< Records the execution of

Qualification Test Result
Product Inventory Asset Physical Asset Human Asset Asset IT Asset

0..n

0..n

Personnel Class Property

Person Property

Intelligent Industrial Systems

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ISA88 Procedural Control model (Equipment/Product Interactions)
Procedure
A Procedure is made up of an ordered set of one or more Unit Procedures

Unit Procedure

A Unit Procedure is made up of an ordered set of one or more Operations

Operation

An Operation is made up of an ordered set of one or more Phases

Phase

Intelligent Industrial Systems

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Product Inventory Asset Physical Asset Human Asset Asset IT Asset

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ISA95 Segment Model
0..n has an execution dependency on

Process Segment
is a collection of

0..n

0..n May be made up of

Process Segment Dependency

0..n

0..n

0..n

0..n

0..n

Process Segment Parameter
0..n May be made up of

Personnel Segment Specification
Has properties of 0..n

Equipment Segment Specification
Has properties of 0..n

Physical Asset Segment Specification
Has properties of 0..n

Material Segment Specification
Has properties of 0..n

0..n Is assembled from

Personnel Segment Specification Property
0..n Corresponds to element in 1..1

Equipment Segment Specification Property
0..n Corresponds to element in 1..1

Physical Asset Segment Specification Property
0..n Corresponds to element in 1..1

Material Segment Specification Property
0..n Corresponds to element in 1..1

Personnel Model

Equipment Model

Physical Asset Model

Material Model

Intelligent Industrial Systems

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Product Inventory Asset Physical Asset Human Asset Asset IT Asset

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ISA95 Operational Activity Model
1.Detailed scheduling 8. Resource management 2. Dispatching 7. Definition management 3. Execution 4. Data collection

5. Tracking

6. Analysis

Production Quality Control Inventory Maintenance
Intelligent Industrial Systems

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Product Inventory Asset Physical Asset Human Asset Asset IT Asset

Other

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Agenda


ISA88 snapshot ISA95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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Production system Lifecycles

Market Demand

Customer Orders / Forecast

Manufacturing

Product R&D

Engineering

Intelligent Industrial Systems

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ISA88 & ISA95 models in Production Lifecycles

ISA-88 models
·

Operations

Recipe Procedural

I S A 8 8 m o d el s
A ct iv it y
·

ISA-95 models
Schedule · Performance
·

ISA-88 models
Process · Recipe Procedural
·

ISA-88 models
Physical · Equipment Procedural
·

ISA-95 models
·

ISA-95 models
Personnel, Equipment, Material · Capability, Segment
·

Product Definition

Product development
Intelligent Industrial Systems

Engineering

I S

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ISA88 & ISA95 Objects in Production Lifecycles
Schedule 3. Operations Requests / Recipes Segments / RPE

Product Definition 1. Product Dévelopment
Intelligent Industrial Systems

Segments PE/RPE

Segments EPE

Capability

Resources Personnel / Equipment / Material

2. Engineering

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Agenda


ISA88 snapshot ISA95 snapshot IIPS Lifecycle CCM modelling framework ISA-88/95 based Models and Objects ISA-88/95 in Production Lifecycles Methodology

Intelligent Industrial Systems

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IAM framework definition overview (see IAP)
P&ID R&D

1b. Physical Modelling
CCM Rules & Tools Use Build Improve

1a. Product Modelling 3. Process Procedural Modelling 4. Segments Modelling 5. Operation Process Modelling

1a. Inventory 1c. Human Modelling Modelling
Object classes and models repository Use Build Improve

2. Equipment Control Modelling

IT modelling

Intelligent Industrial Systems

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Ongoing Industrial Architecture
P&ID R&D

Goveranc e Enabling CCM Rules & Tools Use Build Improve

1b. Physical Modelling

2. Equipment Control Modelling

IS I

/95 -88 A

1a. Product Modelling 3. Process Procedural Modelling

1a. Inventory 1c. Human Modelling Modelling

-9 5 ISA

Persisten ce Object classes and models repository

-88 SA

4. Segments Modelling

-95 5. Operation SA IProcess
Modelling

IT modelling

Use Build Improve

Intelligent Industrial Systems

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Interactions Hierarchy
Business Business Processes
Business Activities

Exécution

(ISA-95, MES)

Operation Processes
Operation Activities

(ISA-88, Equipment Control)

Operating Instructions Procedural Elements

Physical Processes
Recipes, routing 37

Intelligent Industrial Systems

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Examples of Description standards
Business / Operation process Description: BPMN, OSSAD, UML Schedule Requests / Recipes Segments / RPE Product Definition Segments PE/RPE

Product Definition: PPC

Physical Process Description : PFC Capability

Segments EPE

Resources Personnel / Equipment / Material
Intelligent Industrial Systems

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Modular ISA88/95 structure
Entreprise, Site, Area, Work Center, Work Unit

Physical Breakdown

Production, Quality, Inventory, Maintenance

Domains

Object Classes (Templates) Functionnal Objects

Decisional Level
Business Processes, Operation Processes Physical Processes Equipment control Run, Stop, Hold...

Exclusive States
Intelligent Industrial Systems

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Information Elements
Domain Model Std Cliquez sur l'icône pour ajouter un tableauISA-88 Product Asset Process Product ISA-95 Inventory Asset Equipment Asset Material Physical Equipment Physical Asset Personnel Procedural Procedural ISA-95 ISA-88 ISA-95 ISA-95 ISA-88 ISA-88 Information elements Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Operation Processes Activities / Tasks 40

Human Asset Equipment Control Physical Process Control

Physical Process Mngt Segment Operation Process Mngt
Intelligent Industrial Systems

ISA-95 ISA-95

Operation Activity

1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pp

Thank You !

Intelligent Industrial 1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pp Systems

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