Manufacturing Operations Management Dennis Brandl BR&L Consulting
Dennis Brandl
Peter Owen Eli Lilly & Co
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Objectives • 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 provide 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 and provide visibility of production
• The Manufacturing Operations Management models are currently being used in the development of multiple new manufacturing facilities
Dennis Brandl & Peter Owen
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Manufacturing 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 Dennis Brandl & Peter Owen
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Collaborative 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 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 Dennis Brandl & Peter Owen
• 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 5
Philosophical Orientation • Enterprise Management systems:
– How much is my stuff worth? – How much stuff do I have/need? • Manufacturing Operations Systems:
– How do I make my stuff? – Where is my stuff?
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ISA 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” Dennis Brandl & Peter Owen
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ISA 95 Control Hierarchy Levels Level 4
Level 3
Level 2 Level 1 Level 0 Dennis Brandl & Peter Owen
Business Logistics
Plant Production Scheduling, Shipping, Receiving, Inventory, etc
Manufacturing Operations Management Dispatching, Detailed Production Scheduling, Production Tracking, ...
Batch Production Control
Continuous Production Control
Interface addressed in the ISA 95.01 and ISA 95.02 standard Area addressed in the ISA 95.03 standard
Discrete Production Control
The production processes 8
ISA 95 Control Hierarchy Levels
Business Logistics Business Logistics Level 4 Management Interface addressed (ERP) in the ISA 95.01 and ISA 95.02 standard Manufacturing Area addressed Manufacturing Operations Management Level 3 in the ISA 95.03 standard Operations Management (MES, LIMS, AM, …) Plant Production Scheduling, Shipping, Receiving, Inventory, etc
Dispatching, Detailed Production Scheduling, Production Tracking, ...
Level 2 Level 1 Level 0 Dennis Brandl & Peter Owen
Batch Production Control
Continuous Production Control
Discrete Production Control
The production processes 9
ISA 95 Part 1 and Part 2 Exchanged Information Information that crosses the boundary between business systems and manufacturing systems
Dennis Brandl
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Exchanged Information Categories Enterprise Information Plant Production Scheduling, Operational Management, etc
Production Product Production Production Capability Definition Schedule Performance InformationInformation (What to (What was (What is available for use)
(How to make a product)
make and use)
made and used)
Manufacturing Control Information
Area Supervision, Production Planning, Reliability, Assurance, etc Dennis Brandl & Peter Owen
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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
Dennis Brandl & Peter Owen
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Four Resource Object Models Personnel resources managed for production People
Equipment resources managed for production Equipment
Material resources managed for production Materials
Business view of production processes Process Segments Dennis Brandl & Peter Owen
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Capability, Product, Schedule, and Performance Information What is available for use for production Product
Time
Capability/Capacity
What is needed to make a product Product Definitions
What to make and resources to use Production Schedule
What was made and resources actually used Production Performance Dennis Brandl & Peter Owen
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Production Schedule
People
• Production Schedule • Production Request • Segment Request • Expected Produced Material • Expected Consumed Material • Expected Personnel • Expected Equipment • Production Parameters •…
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,…)
Equipment
Materials
Segments Dennis Brandl & Peter Owen
Production Schedule
Per location (Site, Area, …) Per week, day, shift, order, … 15
Production Performance
People
• Production Performance • Production Response • Segment Response • Produced Material Actual • Consumed Material Actual • Personnel Actual • Equipment Actual • Production Data •…
Equipment
What was made - What material was actually produced - What materials were actually consumed - Equipment used - Personnel used - Production data (e.g. Purity, density,…)
Materials
Segments Dennis Brandl & Peter Owen
Production Performance
Per location (Site, Area, …) Per shift, hour, end of batch, … 16
XML 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 V2.0
• One schema for each object model • Formal way to exchange information – www.wbf.org
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An XML Example – Material Lot W89 A lot of material WXE908 Tank 1 4500 dateTimeProduction 2001-01-06T00:14:23+11:30 Quality Status Good
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ISA95 Part 3 Activity Models of Manufacturing Operations In Development Expected Release 2004
Dennis Brandl
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Order Processing (1.0)
Production Scheduling (2.0)
Material and Energy Control (4.0)
Production Control (3.0)
INVENTORY OPERATIONS
Product Inventory Control (7.0)
QUALITY ASSURANCE OPERATIONS MAINTENANCE OPERATIONS Maintenance Management (10.0)
Dennis Brandl & Peter Owen
Product Shipping Admin (9.0)
PRODUCTION OPERATIONS
INVENTORY OPERATIONS
Procurement (5.0)
Product Cost Accounting (8.0)
Quality Assurance (6.0) Marketing & Sales Research Development and Engineering 20
ISA 95.03 Manufacturing Operations Functions
Product definition
Production schedule
Production capability
Production performance
Detailed production scheduling Production resource management
Production tracking Production dispatching
Analysis Production data collection
Product definition management Production execution Equipment and Process Specific Production Rules
Operational Commands
Operational Responses
Equipment and Process Specific Data
Level 2 Process Control
Dennis Brandl & Peter Owen
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Other Enterprise Activities in Manufacturing Operations • Production, Maintenance, Inventory, Quality • Management of information, compliance, security, documentation, and configurations Level 4 Level 3
Inventory Operations
Maintenance Operations Production Operations
Management of Information Quality Operations
Management of Configuration
Management of Security
Management of Documentation
Management of Compliance Activity detailed
Level 2
Activity not detailed Activity outside scope
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Implementations • 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 Dennis Brandl & Peter Owen
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Building Collaborative Manufacturing Systems • Process Used to Develop Solution Architectures – – – – – –
Conceptual Topology Functional Areas Standards and Guidelines Standard Applications Logical Architecture Design Physical Architecture Design
Dennis Brandl & Peter Owen
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ISA 95 Control Hierarchy Levels Level 4
Level 3
Level 2 Level 1 Level 0 Dennis Brandl & Peter Owen
Business Logistics
Plant Production Scheduling, Shipping, Receiving, Inventory, etc
Manufacturing Operations Management Dispatching, Detailed Production Scheduling, Production Tracking, ...
Batch Production Control
Continuous Production Control
ISA – IEC/ISO Interface Standards
ISA Functional Model
IEC, OPC, & OMAC Interface Standards
Discrete Production Control
The production processes 25
Conceptual Topology – IT View • IT View of the ISA-95 Levels and relationship to systems and networks • Levels 1-2 – Control the process and provide visibility to the process – Electronic records are not embedded in the control layers (Level 1-2) – Usually some specialized hardware and possibly networks
• Level 3 – Maintenance of production information is centralized to provide greater control and availability of the records – Electronic records are managed and controlled through Level 3 systems with audit trail, access control, backup, and ERP connectivity – Usually standard hardware and networks
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Conceptual Topology – IT View ERP, APO, Logistics Systems
Level 4 Business Process Information Network
MES, LIMS, WMS, CMM Systems
Level 3 Operations Information Networks
Level 2
HMI, SCADA, Batch Systems Automation Networks
PLC, DCS, Packaged Systems Discrete & Process Device Communication Networks
Level 1 Dennis Brandl & Peter Owen
I/O, Devices, Sensors 27
Functional Areas • Use the ISA 95 and ISA 88 models of functions • Map the functions to system areas and networks • Use the ISA 95 rules for determining what is in Level 3 (vs Level 4) – – – –
The function is critical to plant safety The function is critical to product quality The function is critical to plant reliability The function is critical to maintaining regulatory compliance. • Includes such factors as safety, cGMP, and environmental compliance • Maintaining FDA, EPA, USDA, OSHA, TÜV, EU, EMEA, and other agency compliance
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Business Process Information Network
Production Dispatching
Production Execution Configuration Management
Production Analysis
Operations Information Networks
Level 2
Alarm Management Operator Visibility
Operator Control
Supervisory Control
Equipment Information Collection
Recipe Control
Automation Networks On/Off Control
Continuous Control
Programmed Control
Phase Control
Interlock & Safety Control
Discrete & Process Device Communication Networks
Level 1
Sense Events
Dennis Brandl & Peter Owen
Manipulate Equipment
Networking
Product Definition Management
Sense Process
Networking
Level 3
Production Tracking
Resource Management
Networking
Detailed Scheduling
Networking
Functional Areas – From ISA 95 & 88
Manipulate Process
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Logical Architecture • Maps functional areas and data locations – Independent of technology
• Defines the different layers of the architecture in terms of data and control – These are mapped to physical networks, servers, and applications in the physical architecture
• Defines what functions are to be performed at each level, and what data is to be maintained at each level – To result in maintainable and robust systems – To provide a way to manage the life cycle of the production systems – Provides the structure required to grow and modify the system without compromising any of the previous advantages
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Centralized Servers Desktop
Logical Architecture – IT View Reports and Analysis
Reporting HMI Engineering Tools Investigations, Trends, …
Level 3
Diagnostics, analysis, …
Business Information Network Fault tolerant Permanent Database Operations Control
Site Data Storage ERP Connection Area Data Storage MES Operations Information Network
Production Areas
Operator Control Batch Execution Real-time Data and Buffering Real-time Control and Data Collection
Supervisory HMI Recipe Execution Data Acquisition Automation Network
Controllers Packaged Equipment Sensors/Actuators Process/Equipment
Dennis Brandl & Peter Owen
Level 2
Device Connection & /Networks
Level 1
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A Physical Architecture • Defines the IT infrastructure and applications – – – –
Defines networks and network connections Defines locations of applications Defines locations of servers Defines the mapping of applications to servers
• Physical architecture depends on the solution set used: – – – –
Vendor capabilities Networks Security and network management …
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One Instance Per Site
DataBase Servers Ethernet
Historian Reporter
Network Management Router
Level 3
Domain Ctrl DNS VLAN Switch
2 way Firewall
VLAN Switch
Configuration Server
Eng Tools Diag Tools High Alarm Low Alarm Comm. Err.
MES Server
Domain Ctrl DNS
Non operations tools and views into data
Ethernet
HMI Server Historian Collection Gateway OPC Ethernet Network Management Router
Site Information Network
ERP Connection
Ethernet
Area Operations Information Networks Network Management Router
XML
Physical Architecture – IT View
PLC
High Alarm Low Alarm Comm. Err.
HMI Viewer
Batch Execution
WMS Execution
One Instance Per Process Cell
Automation Networks
DCS
Embedded PC
Packaged Equip
Device Networks
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Level 2
Level 1 33
Conclusions • 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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Status • 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 Dennis Brandl & Peter Owen
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