yokogawa electric corporation yokogawa isa-95 copyright © yokogawa electric corporation april 8,...

Yokogawa Electric Corporation

Yokogawa ISA-95Copyright © Yokogawa Electric CorporationApril 8, 2005

Thursday, April 20, 2023

System Integration usingISA-95

Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005

Outline

What is ISA-95?– Parts 1 & 2 Enterprise-Control System Integration– Part 3 Manufacturing Operations

Yokogawa support for ISA-95– Standard development– Enterprise integration– Manufacturing Operations

Implementing ISA-95– Analysis & Design– Implementation



What is ISA-95?


ISA-95 is Multi-part Standard

Part 1:– ANSI/ISA 95.00.01 “Enterprise - Control System Integration -

Part 1: Models and Terminology”– IEC/ISO 62264-1

• Joint international standard

Part 2:– ANSI-ISA 95.00.02 “Enterprise - Control System Integration -

Part 2: Object Attributes”– IEC/ISO 62264-2

• In final stages of approval

Part 3:– Work in Progress– Models of Manufacturing Operations

SP95 is the committee developing the ISA-95 standards


Why is ISA-95 Needed?

Integration of business and manufacturing systems is difficult– Different systems, cultures, terminology...– Integration projects are expensive– Lack of consensus and models to follow for integration


ISA-95 Provides

Framework for integrating business and control systems

– Separation of the business processes from the manufacturing processes

– Focus on functions, not systems, organizations or individuals

• Can be applied regardless of the degree of automation

– Clear description of exchanged information

Vendor independence

Emphasize on best practices for integration of enterprise and control systems


ISA-95 Benefits

Reduce cost of integrating business systems with manufacturing systems

Vendor independent design tool focuses work on interfaces, not specific products

Results in more robust, loosely coupled systems for lower maintenance costs and lower TCO


ISA-95 Functional Hierarchy

Business Planning & Logistics

Plant Production Scheduling,Operational Management, etc

ManufacturingOperations & Control

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

ContinuousControl

Level 4

Level 3

Levels2,1,0

Parts 1 & 2 addressthis interface

DiscreteControl

BatchControl

ISA-95.00.01 Figure 3

ISA-88Standard

ISA-95Part 3

Standard


ISA-95 Equipment Hierarchy

May contain 1 or more



Lowest LevelsOf Equipment

Typically Scheduled

By Levels 3 or 4

Level 3 activitiestypically deal withthese objects


Must contain 1 or more May contain 1 or more

ProductionUnit

Process Cell

Level 4 activitiestypically deal withthese objects

Lower level equipment usedin repetitive or

discrete operations

Lower levelequipment used

in batch operations

Lower levelequipment used

in continuousoperations


Area

Site

Enterprise

ProductionLine

Unit Work Cell



Categories of Information

Manufacturing operations &control information

Production operations, maintenanceoperations, quality operations, etc.

Business planning &logistics information

Plant production scheduling,operational management, etc.

Productdefinition

information(What must be

defined to makea product)

Productioncapability

information(What resources

are available)

Productionschedule

information(What to

make and use)

Productionresponse

information(What was

made and used)

ISA-95.00.03 Draft 13 Figure 3


Interface Categories

Pro

duct

ion

Res

pons

e

Production

Schedule

Business Planning &Logistics Information

ProductionDefinition

Manufacturing Operations &Control Information

ProductionCapability


Production Capability




• Production Capability

• Input to planning

• What resources are available to be scheduled?

• Personnel

• Equipment

• Material


Product Definition




• Consists of Product Segments

• Each Product Segment specified by

• Product Parameter

• Personnel Specification

• Equipment Specification

• Material Specification


Production Schedule & Response

Pro

duct

ion

Res

pons

e

Production

Schedule



• Matching schedules & responses

• May be broken down into Segments

• Product Parameter

• Personnel

• Equipment

• Material Produced/Consumed

• Consumable


Data Flows for Batch Processes

Pro

duct

ion

Res

pons

e

Production

Schedule





Equipment/Asset Availability

Recipes What to make, when to make it

Batch Record


Enterprise - Control Domain Boundary

FunctionsOutside the

Control Domain(e.g. Production Scheduling)

(e.g. Production Schedule and Production Results)

Information Flows of interest

FunctionsWithin the

Control Domain(e.g. Equipment Monitoring)

Enterprise/Control System Boundary

Functions detailed

Functions not detailed

Data flows detailed

Data flows not detailed



ISA-95 Part 1 & 2 Object Models

Part 1 defines object models to define resources and categories of information to be exchanged– Object models designed using Unified Modeling

Language (UML)– Enable software designs in different languages and

formats to be created

Part 2 defines attributes (or properties) for each object defined in Part 1– Attributes add meaning and detail to the objects


Production Capability and Product Definition are used as inputs to the Enterprise Planning/Scheduling function

Production Schedules exist in different levels of detail. Enterprise plans and schedules are usually course schedules used to create lower level, more detailed schedules.

Production Performance reports actual performance to the Enterprise

Object Models

Resource Object Models

– Personnel

– Equipment

– Material (and Energy)

– Process Segments

Categories of Information Object Models

– Production Capability

– Product Definition

– Production Schedule

– Production Performance

Personnel, Equipment & Material Resources are the basis for all ISA-95 information

These resources may be grouped into segments to partition an area or product definition


Sample Object Model and Attributes

AttributeName

Description Examples

ID A unique identification of a specific piece ofequipment, within the scope of the informationexchanged (Production Capability, ProductionSchedule, Production Performance, …)

The ID is used in other parts of the model whenthe equipment must be identified, such as theproduction capability for this person, or aproduction response identifying the equipment.

R7726

Reactor 101

Lathe machine 33

Description Additional information about the equipment.

ISA-95.00.02EquipmentAttributes

ISA-95.00.01 Equipment

model


Production Schedule

PersonnelRequirement

EquipmentRequirement

MaterialProduced

Requirement

PersonnelModel

EquipmentModel

MaterialModel

Corresponds to element in(see Figure 1)



May contain

0..n 0..n0..n0..n

1..n

PersonnelRequirement

Property

EquipmentRequirement

Property

Material ProducedRequirement

Property

1..n 1..n 1..n

ProductionSchedule

ProductParameter

ProcessParameter

Material ConsumedRequirement


0..n

Material ConsumedRequirement

Property

1..n

ConsumableExpected

0..n

ConsumableExpectedProperty

1..n

SegmentRequirement

1..n

Is made up of

Is made up of

Is associatedto either

Product Segmentor

Process Segment

RequestedSegmentResponse

Correspondsto a

May Correspondto a

ProductionParameter

ProductionRequest

0..n

0..n

1..1

0..n

1..1

0..n

1..1

0..n

1..1

ProductProduction

Rule

Production ScheduleIDStart & End TimeProduction Request

IDStart & End TimeSegment Requirement

IDStart & End TimeParameterPersonnel RequirementEquipment RequirementMaterial Produced

RequirementMaterial Consumed

RequirementConsumable Expected

RequirementSegment Requirement


ISA-95 Part 3

Models of Manufacturing OperationsRecognizes that Enterprise-Control domain boundary will varyFocuses on MES functions in Level 3Many of these functions may be placed in the enterprise or control system domain– Dependant upon the business, company, application

Part 3 defines the functions in Level 3 – Parts 4 and probably 5 will define the data models and

attributes.


Manufacturing Operations

Manufacturing Operations consists of:– Production Operations– Maintenance Operations– Quality Operations– Inventory Operations

Each operations type has unique data that must be exchanged between levels 3 and 4


Activities InsideThe Enterprise Domain(e.g. Production Scheduling) (e.g. Production Schedule)

Part 1 & 2 Information Flows of interest

ActivitiesWithin ManufacturingOperations(e.g. Production Dispatching)

Enterprise/Control System Boundary

Activity detailed

Activity not detailed

Data flows detailed

Data flows not detailed

Level 4

Level 3

Level 2

Part 3 Information Flows

Manufacturing Operations Process Control SystemBoundary

Level 3 MES Functions


ResourceManagement

Analysis

DataCollection

Execution

Dispatching

Tracking

DetailedScheduling

Level 2 Process Control

Definitionmanagement

OperationsCapability

OperationsPerformance

OperationsSchedule

OperationsDefinition

ED

B

A

C

Level 3 & 4 Boundaries Vary

Level 4

Level 3


ProductionResource

Management


ProductionAnalysis

(QA) ProductAnalysis

ProductionData

Collection

ProductionExecution

ProductionDispatching

ProductionTracking

ProductionPerformance

DetailedProductionScheduling

ProductionSchedule


ProductDefinition

Management

ProductDefinition

Part 3 Manufacturing Operations Functions


Inventorydata

collection

Inventoryexecution

Inventory resource

management

Inventorydispatching

Inventorytracking

Inventory

response

Detailedinventoryscheduling

Inventoryrequest

Inventorydefinition

management

Inventoryanalysis

Inventorycapability

Inventorydefinitions

Productiondata

collection

Productionexecution

Productionresource

management

Productiondispatching

Productiontracking

Productionperformance

Detailedproductionscheduling

Productionschedule

Productdefinition

management

Analysis


Productdefinition

MaintenanceData

Collection

MaintenanceExecution

MaintenanceResource

Management

MaintenanceDispatching

MaintenanceTracking

MaintenancePerformance

DetailedMaintenanceScheduling

MaintenanceSchedule

MaintenanceDefinition

Management

MaintenanceRequests

MaintenanceCapability

MaintenanceResponses

MaintenanceAnalysis

MaintenanceDefinitions

Qualityanalysis

Qualitytest datacollection

Quality testexecution

Qualitytest resourcemanagement

Quality testdispatching

Quality testtracking

Quality testperformance

Detailedquality testscheduling

Quality testschedule

Qualitydefinition

management

Quality testrequests

Quality testcapability

Quality testresponses

Qualitydefinitions

Maintenance Production Quality Inventory

X

MES Functional Categories

Level 2


ISA-95 vs. MESA

MESA– Originally “Manufacturing Execution Systems

Association”– Now “Manufacturing Enterprise Solutions Association”

MESA model provided focus for MES– Collection of functions– Systems biased– No detail

ISA-95 Part 3– Functional based– End-user driven

• Purdue Model

– Detailed• Data flows• Objects & Attributes

Operations/Detailed

Scheduling

ResourceAllocation& Status

PerformanceAnalysis

DocumentControl

ProductTracking &Genealogy

DispatchingProduction

Units

MaintenanceManagement

LabourManagement

ProcessManagement

QualityManagement

DataCollectionAcquisition

MES

SupplyChain

Management

EnterpriseResourcePlanning

Product/Process

Engineering

Controls

Sales &Service

Management


Who is Using ISA-95

End users– Using the standard for new integration projects

• Arla Foods• Proctor & Gamble• Nestle• Eli Lilly

ISA-95 provides models for use in analysis B2MML (Business To Manufacturing Markup Language) provides tools for implementation– XML schemas developed by SP95 members working

under the World Batch Forum (WBF)– IT tool for use on integration projects– Standard, vendor neutral, for integration projects



Yokogawa Support for ISA-95


Support for Standards Development

Yokogawa has been active in the creation of all parts of the ISA-95 standardYokogawa developed the B2MML XML Schemas for the World Batch ForumYokogawa contributing our ISA-95 and OPC expertise to create a new Open O&M standard– Open O&M = Open Operations & Maintenance– Integrate ISA-95 operations and maintenance functions

with MIMOSA’s (www.mimosa.org) open system architecture for asset management

– Use OPC as the transport for the Open O&M content


e-RM Architecture based on three chains

MES

Procure-ment

Procure-ment

Mainte

-nanceMainte

-nance

ERP

PCS

FieldSolutions

Produc-tion

Produc-tion

Distri- bution Distri- bution SalesSales

Construc

-tionConstruc

-tion

DesignDesign

Operation

Operation

Engineering Chain(Product Lifecycle

Management)

Engineering Chain(Product Lifecycle

Management)

Enterprise-Production Chain

Enterprise-Production Chain

Supply ChainSupply Chain

ISA-95ISA-95


Integrated Suite of Solutions

Yokogawa offers an integrated suite of proven software tools, designed to support the operational optimization of batch and

continuous process’s

Process Control and Instrumentation

Process Data Historian

Reconciled Operational Information

Operational Excellence Applications

Enterprise Resource Planning

Exaquantum/PIMS/Batch/SERPRM

ExaOMS

Enterprise Resource Planning

ExaSMOC

ExaSPOT

ExaRQE

ExaplogExapilotVisaOA

MVisaEMVisaPMVisaMB

VisaDRVisaPA

ExaopcCS 3000, CS Batch 3000, Stardom

Fieldbus and Instruments

ISA 95 Parts 1 &

2

ISA 95 Part 3


Part 1 & 2 Solutions

Enterprise-Control System Integration– ISA-95 used for integration architecture– B2MML (Business To Manufacturing Markup Language)

used for implementation• Customized as required for each project

Focuses on Production Schedule & Response– Largest demand is for ERP-PAS integration– Leading ERP system for

industries is SAP

SAP R/3 integration – PP-PI – Production Planning

for Process Industries– PM – Plant Maintenance– MM – Materials Management


Production

Definition


Production

Capability

ProductionSchedule

ProductionResponse


Enterprise-Control Integration

Intelligent Instruments

CS Batch 3000

OPC

Exaquantum/Batch

OP

CO

PC

IntelligentEquipment DCSs, PLCs

LIMS

Enterprise Systems(SAP, Oracle,…)

Manufacturing Operations & Control Information


Production

Definition

ProductionSchedule

ProductionResponse

Production

Capability

Plant Resource Manager

B2MML Adapter (ISA-95)



Production Response

Exaquantum/Batch




ProductionSchedule

ProductionResponse

Production Response– Specified response part

of Production Schedule, or– Configured as part of B2MML

interface

Exaquantum/Batch organizes data by Production Run (Batch)– All results data stored in integrated

database– Includes data from beyond the DCS

• LIMS• Packaging• Manual Activities

Exaquantum/Batch B2MML adapter builds Production Response and transmits to Enterprise level B2MML adapter




Production Capability

Exaquantum/Batch



Business Planning &Logistics InformationCapability information used as

input to planning & schedulingCapability =– Equipment– Personnel– MaterialAvailable for production

operations

Manufacturing operations contributes asset availability data to enterprise systems



Production

Capability

Capaci

ty

Pro

du

ctio

n

Cap

aci

ty

Unattainable Capacity

Available Capacity

Committed Capacity

Time

Current Production Capacity

Requires tight Operations & Maintenance integration

Material & Personnel data usually available in the Enterprise

domain, not the Control domain


Product Definition

Exaquantum/Batch



Business Planning &Logistics InformationProduct Definition is very

process/industry specific– Continuous

• Small factor, sometimes collections of formula/setpoints

• Good fit for B2MML

– Batch• Recipe driven• ISA-88.00.03 defines General &

Site Recipes• Implement outside of B2MML

depending upon General/Site Recipe system

– Discrete• BOM driven• Implementation method

depends upon Enterprise & Control Systems



Production

Definition

Enterprise requirements drive data flow direction & content


Benefit of B2MML

Decouples Enterprise & Control systems– Fewer dependencies increases

robustness

Vendor neutralStandards basedEnables common data format when multiple manufacturing sites are integratedCommon industry approach– Arla Foods– Nestle– Proctor & Gamble

Defacto standard among end-users for ISA-95 implementations

Exaquantum/Batch


Manufacturing Operations & Control

Information

Business Planning &Logistics

Information

ProductionSchedule

ProductionResponse




Part 3 Solutions

Manufacturing Operations– Production Operations

• Intelligent Field Instruments• Plant Resource Management• Distributed Control Systems• Network Control Systems• Plant Information Systems• Advanced Operation Assistance

– Maintenance Operations• Maximo

– Quality Operations• LIMS Integration

– Inventory Operations• Warehouse Management System Integration

Part 3 is still under development.

When the standard is released Yokogawa will

support the development of B2MML extensions

B2MML XML schemas will be the preferred data

exchange format for ISA-95 Part 3 Data


Productionresource

management


Productionanalysis

(QA) Productanalysis

Productiondata

collection

Productionexecution

Productiondispatching

Productiontracking

ProductionPerformance

Detailedproductionscheduling

Productionschedule


Productdefinition

management

ProductDefinition

Production Operations Support

Exaquantum/Batch

3rd Party Scheduling Packages

CS Batch 3000

CS Batch 3000Smart Field

InstrumentsNetworkSolution

s

AdvancedOperation Assistance


Production Operations

Centered on Process Automation Systems– Production management

• Controlling production, not just the process

– Process optimization• Advanced Operations Assistance

– Production analysis• Exaquantum/Batch provides product and production

analysis data

OPC is the preferred transport for production operations dataWhen ISA-95 Production Operations standard is completed B2MML will be expanded to support maintenance data


Maintenanceresource

management

MaintenanceCapability

Maintenanceanalysis

Maintenancedata

collection

Maintenanceexecution

Maintenancedispatching

Maintenancetracking

MaintenanceResponse

DetailedMaintenancescheduling

MaintenanceRequest


Maintenancedefinition

management

MaintenanceDefinition

Maintenance Operations

Relationship with MRO for Asset Management– Maximo

MIMOSA – Vendor consortium to

exchange asset data– Goal is to enable the

exchange of asset and maintenance data between different vendors system

OPC is the preferred transport for maintenance dataWhen ISA-95 Maintenance Operations standard is completed B2MML will be expanded to support maintenance data


Quality TestResource

Management

Quality TestCapability

Quality Performance

Analysis

Quality TestData

Collection

Quality TestExecution

Quality TestDispatching

Quality TestTracking

Quality TestResponse

DetailedQuality TestScheduling

Quality TestRequest


Quality TestDefinition

Management

Quality TestDefinition

Quality Operations

Quality operations centered around Laboratory Information Systems (LIMS) Key production data moved to Exaquantum/Batch– Part of permanent

batch record– Assembled into B2MML

Production Response

OPC is the preferred transport for LIMS dataWhen ISA-95 Quality Operations standard is completed B2MML will be expanded to support quality data


InventoryResource

Management

InventoryCapability

Inventory Analysis

Inventory DataCollection

InventoryExecution

InventoryDispatching

InventoryTracking

InventoryResponse

Detailed InventoryScheduling

InventoryRequest


InventoryDefinition

Management

InventoryDefinition

Inventory Operations

Inventory operations centered around Warehouse Management Systems and ERP material managementCustom integration ofinventory systemsOPC is the preferred transport for inventory dataWhen ISA-95 Inventory Operations standard is completed B2MML will be expanded to support inventory data


Summary

Yokogawa believe ISA-95 is a valuable standard for the industryWe are committed to continuing to support its development and adoptionISA-95 is Yokogawa’s preferred format for:– Enterprise-Control System Integration– Level 3 (MES) System Integration

B2MML (Business To Manufacturing Markup Language) is Yokogawa’s preferred means for implementing ISA-95– Adopted by leading manufacturing companies– Mainstream information technology

ISA-95 implementations require careful planning and customized implementation

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