1. Manufacturing Operations Management
Dennis Brandl Peter Owen
BR&L Consulting Eli Lilly & Co

2. 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 also include 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
The Manufacturing Operations Management models are currently being used in the development of multiple new manufacturing facilities

3. 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

4. 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

5. 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
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

6. Philosophical Orientation
Enterprise Management systems:
How much is my stuff worth?
Manufacturing Opearations Systems:
Where is my stuff?

7. ISA 95 Provides Direction
The ANSI/ISA “Enterprise - Control System Integration - Part 1: Models and Terminology”
Also Draft International Standard ISO/IEC
ANSI/ISA “Enterprise - Control System Integration - Part 2: Object Attributes”
Draft ISA “Enterprise - Control System Integration - Part 3: Activity Models of Manufacturing Operations Management”
Explain a little bit about ISA and what it does in the standards area.
ISA Is the Instrumentation Systems and Automation society
Explain the S95.01 is the draft standard and that SP95 was the committee.
Mention that this is a USA standard, under the auspices of ANSI
explain the status of the international version and the draft Part 3 work.

8. ISA95.01 Levels Level 4 Business Planning & Logistics Level 3
Plant Production Scheduling,
Operational Management, etc
Interface addressed
in the ISA and
ISA standard
Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Area addressed
in the ISA 95.03
standard
Levels
2,1,0
The figure above is a simplified version of the Purdue model, showing the S95 scope.
Level 4 is high level planning and scheduling and logistics.
Level 3 is manufacturing control,
including operations scheduling - or planning.
Level 2 needs a lot of definition.
Describe S88.01 and the batch model and how it stops at the process cell.
Describe some of the S88.01 models.
There are less well-defined models for continuous and discrete processes.
Continuous is handled somewhat by S88.01, but without the concept of recipes for products, just recipes for product startup and shutdown.
PDXI has a model at least of all of the static information (design of P&IDs) and control loops, but not very dynamic
Discrete models
SME (Society of Mechanical Engineers has some material, but nothing in the ISA /IEC/ISO arena.
Batch
Control
Continuous
Control
Discrete
Control

9. Operations Management
ISA95.01 Levels
Business Logistics
Management
(ERP)
Level 4
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Interface addressed
in the ISA and
ISA standard
Manufacturing
Operations Management
(MES, LIMS, AM, …)
Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Area addressed
in the ISA 95.03
standard
Levels
2,1,0
The figure above is a simplified version of the Purdue model, showing the S95 scope.
Level 4 is high level planning and scheduling and logistics.
Level 3 is manufacturing control,
including operations scheduling - or planning.
Level 2 needs a lot of definition.
Describe S88.01 and the batch model and how it stops at the process cell.
Describe some of the S88.01 models.
There are less well-defined models for continuous and discrete processes.
Continuous is handled somewhat by S88.01, but without the concept of recipes for products, just recipes for product startup and shutdown.
PDXI has a model at least of all of the static information (design of P&IDs) and control loops, but not very dynamic
Discrete models
SME (Society of Mechanical Engineers has some material, but nothing in the ISA /IEC/ISO arena.
Batch
Control
Continuous
Control
Discrete
Control

10. ISA 95 Part 1 and Part 2 Exchanged Information
Information that crosses the boundary between business systems and manufacturing systems
This is the intro slide to the discussion on Part 1 and Part 2 which defines the exchanged information.

11. Exchanged Information Categories
Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Production
Capability
Information
(What is
available
for use)
Product
Definition
Information
(How to make
a product)
Production
Schedule
(What to
make and
use)
Production
Performance
(What was
made and
used)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc

12. 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

13. Four Resource Object Models
People
Materials
Equipment
Personnel resources managed for production
Equipment resources managed for production
Material resources managed for production
Process Segments
Business view of production processes

14. Capability, Product, Schedule, and Performance Information
Time
Capability/Capacity
What is available for use for production
Product
Definitions
What is needed to make a product
Production
Schedule
What to make and resources to use
Once the “WORDS” are agreed to then we can talk about the real exchange of information, things that may change on a regular basis.
These correspond to the four bubbles in the VENN diagram previous used:
What is available, what is needed for a product, what to do, and what was done.
Production
Performance
What was made and resources actually used

15. Production Schedule Production Schedule Production Request
People
Materials
Equipment
Segments
Production
Schedule
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,…)
This is what people normally think about when they think about B2M integration. These are the production schedules. There is a formal UML model that defines a production schedule, in terms of the personnel, equipment, material, process segment, and product definitions.
It may define priorities, due dates, latest start dates, etc..
It may define what materials to use, what equipment to use, and what personnel to use.
(Note, add in the story here about not specifying too much detail, where the ERP system was specifying the bags of sugar, irrespective of their location in the warehouse)
Mention options (e.g. such as color, or customer options, such as purity range or filler %)
Per location (Site, Area, …)
Per week, day,
shift, order, …

16. Production Performance
People
Materials
Equipment
Segments
Production
Performance
Production Performance
Production Response
Segment Response
Produced Material Actual
Consumed Material Actual
Personnel Actual
Equipment Actual
Production Data …
What was made
What material was actually produced
What materials were actually consumed
Equipment used
Personnel used
Production data (e.g. Purity, density,…)
This the last element of shared information, and it is what manufacturing tells the business about what was done.
This is what was produced, what was consumed, what consumables where used, what personnel was used, and what equipment was used.
PROVIDED THE BUSINESS SYSTEMS ARE READY TO ACCEPT THAT INFORMATION.
Mention that only a fraction of a percent of the generated information is actually exchanged. Use the chemical plant as an example, 100 GB of data generated per week, 1 GB of data stored, > 1MB of data exchanged ( % of data collected is exchanged).
Per location (Site, Area, …)
Per shift, hour,
end of batch, …

17. 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
One schema for each object model
Formal way to exchange information

18. An XML Example – Material Lot
<ID> W89 </ID>
<Description> A lot of material </Description>
<MaterialDefinitionID> WXE908 </MaterialDefinitionID>
<Location> Tank 1 </Location>
<Quantity
UnitOfMeasure = "KL" > 4500
</Quantity>
<MaterialLotProperty>
<ID> dateTimeProduction </ID>
<Value> T00:14:23+11:30 </Value>
</MaterialLotProperty>
<ID> Quality Status </ID>
<Value> Good </Value>
</MaterialLot>
</Material>

19. ISA95 Part 3 Activity Models of Manufacturing Operations
In Development
Expected Release 2004

20. PRODUCTION OPERATIONS QUALITY ASSURANCE OPERATIONS MAINTENANCE
Order
Processing
(1.0)
Product Cost
Accounting
(8.0)
Product
Shipping Admin
(9.0)
Production
Scheduling
(2.0)
PRODUCTION
OPERATIONS
INVENTORY
OPERATIONS
Material and
Energy Control
(4.0)
Production
Control
(3.0)
Product
Inventory Control
(7.0)
INVENTORY
OPERATIONS
QUALITY
ASSURANCE
OPERATIONS
Procurement
(5.0)
MAINTENANCE
OPERATIONS
Quality
Assurance
(6.0)
Marketing
& Sales
Maintenance
Management
(10.0)
Research Development
and Engineering

21. ISA 95.03 Manufacturing Operations Functions
Production
resource
management
capability
Analysis
data
collection
execution
dispatching
tracking
performance
Detailed
production
scheduling
schedule
Level 2 Process Control
Product
definition
Equipment and Process
Specific Production Rules
Specific Data
Operational
Responses
Commands

22. Other Enterprise Activities in Manufacturing Operations
Some actives are not specific to manufacturing
ISA lists references to standards in these areas
Quality
Operations
Maintenance
Production
Level 4
Level 3
Level 2
Management
of Configuration
of Information
of Security
of Documentation
of Compliance
Inventory
Major
Activities
Within
Manufacturing
Operations
Activity detailed
Activity not detailed
Activity outside scope

23. Implementations Nestle Arla Foods Empersas Polar Eli Lilly
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

24. 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

25. ISA 95 Control Hierarchy Levels
Business Logistics
Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
ISA – IEC/ISO Interface
Standards
Level 3
ISA
Functional
Model
Manufacturing
Operations Management
Dispatching, Detailed Production
Scheduling, Production Tracking, ...
IEC, OPC, & OMAC Interface
Standards
Level 2
Batch
Production
Control
Continuous
Production
Control
Discrete
Production
Control
Level 1
Level 0
The production processes

26. 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

27. Conceptual Topology – IT View
Level 4
ERP, APO, Logistics Systems
Business Process Information Network
Level 3
MES, LIMS, WMS, CMM Systems
Operations Information Network
Level 2
HMI, SCADA,
Batch Systems
Automation Network
PLC, DCS,
Packaged Systems
Level 1
Discrete & Process Device Communication Networks
I/O, Devices, Sensors

28. 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 maintaining regulatory compliance.
Includes such factors as safety, cGMP, and environmental compliance
The function is critical to plant safety
The function is critical to product quality
The function is critical to plant reliability

29. Functional Areas – From ISA 95 & 88
Business Process Information Network
Networking
Level 3
Detailed Scheduling
Resource Management
Production Tracking
Product Definition Management
Production Dispatching
Configuration Management
Production Analysis
Production Execution
Networking
Operations Information Network
Level 2
Recipe Control
Supervisory Control
Alarm Management
Operator Control
Operator Visibility
Equipment Information Collection
Networking
Automation Network
Phase Control
On/Off Control
Continuous Control
Programmed Control
Interlock & Safety Control
Level 1
Discrete & Process Device Communication Networks
Networking
Sense Events
Sense Process
Manipulate Equipment
Manipulate Process

30. 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

31. Logical Architecture – IT View
Level 3
Reports and
Analysis
Reporting HMI
Engineering Tools
Desktop
Investigations, Trends, …
Diagnostics, analysis, …
Business Information Network
Fault tolerant
Site Data Storage
ERP Connection
Centralized
Servers
Permanent Database
Area Data Storage
MES
Operations Control
Level 2
Supervisory HMI
Recipe Execution
Operator Control
Batch Execution
Operations Information Network
Real-time Data
and Buffering
Data Acquisition
Production Areas
Automation Network
Real-time Control and
Data Collection
The production area does not indicate locations within the specific zone of production, but is within the scope of control of the production area, with a local network used only for the local production area. This is a separate network segment used to communicate between between controllers and data acquisition systems. There is no physical connection between the local industrial network and any site or wider area network. The local industrial network may be connected to a management VLAN to allow remote monitoring of the network. (See the physical architecture)
Management of the network must be considered. The organization that has ownership and support for the network may be considered as part of each project.
Part of the physical network architecture should follow the Lilly standard for management VLANs. (Check with Wayne Urton)
Note: Don’t assume that the local work centers will always communicate synchronsly, design the system so that they can operate asyschronously.
Controller
Packaged Equipment
Level 1
Device Connection & /Networks
Sensors/Actuators
Process/Equipment

32. 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 …

33. Physical Architecture – IT View
XML
Level 3
DataBase
Servers
Historian
Reporter
DNS
Domain Ctrl
ERP
Connection
Site
Information
Network
VLAN
Switch
2 way Firewall
Network
Management
Router
Comm. Err.
Low Alarm
High Alarm
Eng Tools
Diag Tools
Configuration
Server
MES
Server
DNS
Domain Ctrl
VLAN
Switch
Non operations tools
and views into data
Area Operations Information Network
Level 2
Gateway
Historian
Collection
HMI Server
OPC
Ethernet
Network
Management
Router
Comm. Err.
Low Alarm
High Alarm
HMI
Viewer
Batch
Execution
One Instance Per
Process Cell
Automation Network
Level 1
Ethernet
Network
Management
Router
PLC
DCS
Embedded PC
Packaged Equip

34. 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

35. Status ISA95.00.01 & ISA.95.00.02 available
IEC/ISO available from IEC & ISO
ISA 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