enterprise pi as an enabler for an integrated...
TRANSCRIPT
© Copyright 2011, OSIsoft LLC. All rights Reserved.
Enterprise PI Enabling an
Integrated Manufacturing Landscape
Barry Higgins – Janssen Biologics Ireland
2 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Agenda
• Background
• Enabling MES
• Introducing PI Asset Framework (PI AF)
• MES data interface using PI AF
3 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Agenda
• Background
• OSIsoft and J&J
• Enabling MES
• Introducing PI Asset Framework (PI AF)
• MES data interface using PI AF
4 © Copyright 2011, OSIsoft LLC. All rights Reserved.
About Janssen
• 3 Main areas:
• Consumer
• Medical devices & diagnostics
• Prescription Products
• JSC API Supply Chain.
• Chemicals – 6 sites
• Biologics – 5 sites
5 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Agenda
• Background
• OSIsoft and J&J
• Enabling MES
• Introducing PI Asset Framework (PI AF)
• MES data interface using PI AF
6 © Copyright 2010, OSIsoft LLC. All rights Reserved.
Control Systems Overview
38%
43%
19%
JSC API - PCS Landscape
DCS
PLC
BMS
45%
26%
29%
JSC API – DCS Vendors
Emerson
Siemens
ABB 67%
24%
4% 5%
JSC API – PLC Vendors
Siemens
Rockwell
GE
Other
Various BMS’s
Emerson DeltaV
GE Unicorn
Siemens PCS7
ABB 800xA
Various PLC’s/ Instruments
7 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Various BMS’s
Why do we need the OSIsoft PI System?
• Very disparate systems landscape
– ranging from distributed process control systems
with inherent historian capability to stand-alone
instruments with paper printouts
• Require capability to capture and aggregate
data for visualisation, reporting & analysis
Emerson DeltaV
GE Unicorn
Siemens PCS7
ABB 800xA
Various PLC’s/ Instruments
BMS – Building Management System PLC – Programmable Logic Controller
OSI PI = System Independent Enterprise Data Presentation Layer
8 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Philosophy for OSIsoft PI System in J&J
Pharma
• Get away from counting “tags”
• Collect all data (GMP & non-GMP)
– Process, Alarm & Events, Batch Events
• Deliver a consistent infrastructure globally
– no differentiation from Commercial to R&D
• Provide common visualisation (thick & thin clients)
– Consolidated data visualization for improved process
monitoring and historical batch analysis
– Consolidated alarm reporting for building management, process
control, laboratory equipment, utility systems, warehouse
equipment…
• Targeted compliant reporting (RtReports)
– Autoclaves, washers (non-MES related!)
Lab Instruments
CDS
Process Instruments
Systems Landscape Positioning
CDS: Chromatography Data Software ELN: Electronic Laboratory Notebook ERP: Enterprise Resource Planning LES: Laboratory Execution System LIMS: Laboratory Information Management System MES: Manufacturing Execution System PCS: Process Control System PIMS: Production Information Management System
S95
Level 4
Level 3
Level 2
Level 1
PCS
ERP
MES
LIMS LES
ELN
PIMS
10 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Agenda
• Background
• OSIsoft and J&J
• Enabling MES
• Introducing PI Asset Framework (PI AF)
• MES data interface using PI AF
11 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Where does the PI System fit ?
Production Data
Collection
Production Execution
Management
Production Resource
Management
Production Dispatching
Production Tracking
Production performance
Detailed Production Scheduling
Production schedule
Product Definition
Management
Production level 1-2 functions
Production Performance
Analysis
Production capability
Product definition
Equipment and process specific production rules
Equipment and process specific data
Operational responses
Operational commands
MES
OSIsoft PI
12 © Copyright 2010, OSIsoft LLC. All rights Reserved.
Enabling MES
Production order status Material consumptions Inventory update
Master material data Overall inventory
Material lot status Production orders
Sample IDs
Actu
al
valu
es
Process Control System(s)
ERP
PAS|X
Material Master Overall Inventory Overall Genealogy Master Batch Record Master Production Schedule Production Orders
Production Resource Management Detailed Master Batch Records Production Plan Execution Electronic Batch Recording Weigh & Dispense Review by Exception Material Management in Production
Training Management
Building Automation System(s)
DMS SOP’s / WI’s Drawings Instructions
IPC instruments
LIMS
J&J Users (LDAP / AD)
CAPA
Set
valu
es
Tele
gra
ms
Login verification
UserID & PW
Doc
ID
File
Manual Interface
Synchro
niz
ation
Pro
cess d
ata
Ala
rm &
Events
Manual Interface
Global
MES
Local
Pro
cess d
ata
, Batc
h d
ata
, Ala
rm &
Events
Real-time Information Management System
Scales &
Printers
13 © Copyright 2010, OSIsoft LLC. All rights Reserved.
The New Trinity
• PAS|X Commands & setpoints to Process Control System
• Process Data collected in the PI System
• The PI System data referenced in the PAS|X EBR
• PAS|X EBR batch execution data referenced in the PI
System.
Process Control System(s)
PI System
14 © Copyright 2010, OSIsoft LLC. All rights Reserved.
• Background
• OSIsoft and J&J
• Enabling MES
• Introducing PI Asset Framework (PI AF)
• MES data interface using PI AF
15 Value now. Value over time. © Copyright 2011, OSIsoft, LLC. All rights Reserved.
Real-Time Data Infrastructure: A Key Enabler
Level 4
Level 3
Level 2
Level 1
Level 0
Business Planning & Logistics Plant Production scheduling, Operational Management, etc.
Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling,
Production Tracking, etc.
Batch
Control
Continuous
Control
Discrete
Control
S95 Model
Real-Time Data Infrastructure Common Data Presentation Layer
Process data, Building automation data,
Alarm & Events
Op
erati
on
al C
om
man
ds
Syn
ch
ro
niz
ati
on
EWI Batch Context EWI Data
Template ELEMENT
ELEMENT
ELEMENT
Collections of reusable Elements
Connectivity
Hierarchy
Role based
Assets
Other Data
Process Data / Events
PI Asset Framework
• Data structured and organized by asset
• Spans multiple PI Systems
• Incorporates non time series data
Honeywell ABB
…
Time Series Data Sources
OPC
Interface
XML
Interface
Modbus
Interface
SNMP
Interface
Generic Interfaces
Honeywell
Interface
ABB
Interface
Delta-V
Interface
Rockwell
Interface
Vendor Specific Interfaces
PI Server 2
Delta-V Rockwell Other Honeywell ABB Delta-V Rockwell Other
…
Time Series Data Sources
OPC
Interface
XML
Interface
Modbus
Interface
SNMP
Interface
Generic Interfaces
Honeywell
Interface
ABB
Interface
Delta-V
Interface
Rockwell
Interface
Vendor Specific Interfaces
PI Server 1 Non Time Series Data Sources
…
SCM RDBMS MES
PI AF 2.0 Asset-Equipment Centric access to the Data
17 © Copyright 2011, OSIsoft LLC. All rights Reserved.
Introducing PI Asset Framework
• What is PI Asset Framework ? – “Process Object Models”
which represent the logical components in your process.
– Allows data from multiple PI servers to be combined in one common view.
– Allows the user access to non PI data sources, e.g. external databases.
– Allows process specialists to build process relative models without the need for extensive PI System knowledge.
18 © Copyright 2011, OSIsoft LLC. All rights Reserved.
PI AF in Janssen
• Super Class concept.
– Class based templates – built
in conjunction with process
and subject matter experts.
– Only process critical
information grouped
together in a logical model.
– Ensures that the entire
organisation have a common
taxonomy.
• PAS|X \ PI AF
– Using Unit based templates
allows us to build unit based
MBR elements that can be
applied on other sites.
19 © Copyright 2011, OSIsoft LLC. All rights Reserved.
• Background
• OSIsoft and J&J
• Enabling MES
• Introducing PI Asset Framework (PI AF)
• MES data interface using PI AF
20 © Copyright 2011, OSIsoft LLC. All rights Reserved.
From PI AF to MES and back
PI AF Element Templates
•Class based template.
•Unit Elements created from template.
Upload from PI AF
•Class based PCS MBR elements
•Building blocks for MBR modellers
MBR Generation
•Class based MBR
EBR Execution
•Unit resolved at run-time. •Data retrieved from PI AF Unit Element
Thank you
© Copyright 2010 OSIsoft, LLC.
777 Davis St., Suite 250 San Leandro, CA 94577
Acknowledgements: J&J:
Terry Murphy Barry Lawlor
OSIsoft: Todd Brown Marc Gallant Glenn Hummell Chris Nelson
TQS: Tom Quilty Cathal Horgan
22 © Copyright 2011, OSIsoft LLC. All rights Reserved.
The New Trinity!
• PAS|X Commands & setpoints to Process Control System
• Process Data collected in OSI PI
• OSI PI data referenced in the PAS|X EBR
Process Control System(s)
OSI PI
23 Value now. Value over time. © Copyright 2011, OSIsoft, LLC. All rights Reserved.
Challenges at Level 2: Variable Control System Landscape
Level 4
Level 3
Level 2
Level 1
Level 0
Business Planning & Logistics Plant Production scheduling, Operational Management, etc.
Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling,
Production Tracking, etc.
Batch
Control
Continuous
Control
Discrete
Control
Out of S88 Scope
Typical DCS Vendors
Vendor F
Vendor G
Vendor C
Typical PLC Vendors
Vendor A
Vendor B
Vendor C
Vendor D
Vendor E
Typical Process Control System Landscape
DCS
PLC
BMS
24 Value now. Value over time. © Copyright 2011, OSIsoft, LLC. All rights Reserved.
Real-Time Data Infrastructure: A Key Enabler
Level 4
Level 3
Level 2
Level 1
Level 0
Business Planning & Logistics Plant Production scheduling, Operational Management, etc.
Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling,
Production Tracking, etc.
Batch
Control
Continuous
Control
Discrete
Control
S95 Model
Real-Time Data Infrastructure Common Data Presentation Layer
Process data, Building automation data,
Alarm & Events
Op
erati
on
al C
om
man
ds
Syn
ch
ro
niz
ati
on
EWI Batch Context EWI Data
PI
Server 1
Non Time Series Data Sources
…
Asset RDBMS LIMS
Asset/Equipment centric access to information
PI
Server 2
ELEMENT
ATTRIBUTE WITH UOM i.e. FlowRate l/h
ATTRIBUTE WITH UOM
ATTRIBUTE WITH UOM i.e. LastCalibration
UOM Units of Measurement
NON TIMESERIES
DATA SOURCES
TIMESERIES
DATA SOURCES
TIMESERIES
DATA SOURCES
TAG
Data reference TAG
25 Value now. Value over time. © Copyright 2011, OSIsoft, LLC. All rights Reserved.
Real-Time Data Infrastructure: A Key Enabler
Level 4
Level 3
Level 2
Level 1
Level 0
Business Planning & Logistics Plant Production scheduling, Operational Management, etc.
Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling,
Production Tracking, etc.
Batch
Control
Continuous
Control
Discrete
Control
S95 Model
Real-Time Data Infrastructure Common Data Presentation Layer
Process data, Building automation data,
Alarm & Events
Op
erati
on
al C
om
man
ds
Syn
ch
ro
niz
ati
on
EWI Batch Context EWI Data
Honeywell ABB
…
Time Series Data Sources
OPC Interface
XML Interface
Modbus Interface
SNMP Interface
Generic Interfaces
Honeywell Interface
ABB Interface
Delta-V Interface
Rockwell Interface
Vendor Specific Interfaces
PI Server 1
Delta-V Rockwell Other
Process Control System Landscape with PI
DCSPLC
BMS
26 Value now. Value over time. © Copyright 2011, OSIsoft, LLC. All rights Reserved.
Phases / Sequences
Recipes
Real-Time Data Infrastructure: A Key Enabler
Level 4
Level 3
Level 2
Level 1
Level 0
Business Planning & Logistics Plant Production scheduling, Operational Management, etc.
Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling,
Production Tracking, etc.
Batch
Control
Continuous
Control
Discrete
Control
Recipe
Procedure
Recipe
Unit Procedure
Recipe
Operation
Recipe
Phase
Equipment
Phase
Equipment
Module
Control
Module 2.1
2.2
2.3
2.4
S88 Model S95 Model
Real-Time Data Infrastructure Common Data Presentation Layer
Process data, Building automation data,
Alarm & Events
Op
erati
on
al C
om
man
ds
Syn
ch
ro
niz
ati
on
Equip. Context, Batch Context
Batch Data
EWI Batch Context EWI Data