enterprise pi as an enabler for an integrated ... petroquimica y... · real-time data...

© 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


Agenda

• Background

• OSIsoft and J&J

• Enabling MES




About Janssen

• 3 Main areas:

• Consumer

• Medical devices & diagnostics

• Prescription Products

• JSC API Supply Chain.

• Chemicals – 6 sites

• Biologics – 5 sites


Agenda

• Background

• OSIsoft and J&J

• Enabling MES




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


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


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


Agenda

• Background

• OSIsoft and J&J

• Enabling MES




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


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


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.


PI System


• Background

• OSIsoft and J&J

• Enabling MES



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

…


OPC

Interface

XML

Interface

Modbus

Interface

SNMP

Interface

Generic Interfaces

Honeywell

Interface

ABB

Interface

Delta-V

Interface

Rockwell

Interface


PI Server 1 Non Time Series Data Sources

…

SCM RDBMS MES

PI AF 2.0 Asset-Equipment Centric access to the Data


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.


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.


• Background

• OSIsoft and J&J

• Enabling MES




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


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


OSI PI

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Challenges at Level 2: Variable Control System Landscape

Level 4

Level 3

Level 2

Level 1

Level 0




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



Level 4

Level 3

Level 2

Level 1

Level 0




Batch

Control

Continuous

Control

Discrete

Control

S95 Model



Alarm & Events

Op

erati

on

al C

om

man

ds

Syn

ch

ro

niz

ati

on


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



Level 4

Level 3

Level 2

Level 1

Level 0




Batch

Control

Continuous

Control

Discrete

Control

S95 Model



Alarm & Events

Op

erati

on

al C

om

man

ds

Syn

ch

ro

niz

ati

on


Honeywell ABB

…


OPC Interface

XML Interface

Modbus Interface

SNMP Interface

Generic Interfaces

Honeywell Interface

ABB Interface

Delta-V Interface

Rockwell Interface


PI Server 1

Delta-V Rockwell Other

Process Control System Landscape with PI

DCSPLC

BMS


Phases / Sequences

Recipes


Level 4

Level 3

Level 2

Level 1

Level 0




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



Alarm & Events

Op

erati

on

al C

om

man

ds

Syn

ch

ro

niz

ati

on

Equip. Context, Batch Context

Batch Data


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