System Integration using ISA-95 Monday, April 24, 2017

Yokogawa support for ISA-95 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 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 Explain a little bit about ISA and what it does in the standards area. ISA Is the international society for measurement and control Formally the Instrument Society of America Explain the 95.01 is the standard and that SP95 was the committee. Mention that this is a USA standard, under the auspices of ANSI

Integration of business and manufacturing systems is difficult 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 The slides with this style clip art are from Dennis Brandl of BR&L Consulting (his own company). If these are used the clip art should be replaced so we are not using his material directly.

Framework for integrating business and control systems 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 IT systems should not open valves And, Manufacturing systems should not cut checks Important, and often difficult, to agree upon the data to exchange – especially the details and perspective of the data

Reduce cost of integrating business systems with manufacturing 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 Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Parts 1 & 2 address this interface Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... ISA-88 Standard ISA-95 Part 3 Standard Levels 2,1,0 Batch Control Continuous Control Discrete Control ISA-95.00.01 Figure 3

ISA-95 Equipment Hierarchy Enterprise May contain 1 or more Level 4 activities typically deal with these objects Site May contain 1 or more Area May contain 1 or more May contain 1 or more May contain 1 or more Lowest Levels Of Equipment Typically Scheduled By Levels 3 or 4 Production Unit Production Line Level 3 activities typically deal with these objects Process Cell Must contain 1 or more May contain 1 or more Unit Work Cell Lower level equipment used in batch operations Lower level equipment used in continuous operations Lower level equipment used in repetitive or discrete operations ISA-95.00.01 Figure 4

Categories of Information Business planning & logistics information Plant production scheduling, operational management, etc. Production capability information (What resources are available) Product definition information (What must be defined to make a product) Production schedule information (What to make and use) Production response information (What was made and used) Manufacturing operations & control information Production operations, maintenance operations, quality operations, etc. ISA-95.00.03 Draft 13 Figure 3

Logistics Information Manufacturing Operations & Interface Categories Business Planning & Logistics Information Production Schedule Production Capability Production Definition Production Response Manufacturing Operations & Control Information

Production Capability Business Planning & Logistics Information Production Capability Input to planning What resources are available to be scheduled? Personnel Equipment Material Production Capability Manufacturing Operations & Control Information

Logistics Information Manufacturing Operations & Product Definition Business Planning & Logistics Information Consists of Product Segments Each Product Segment specified by Product Parameter Personnel Specification Equipment Specification Material Specification Production Definition Manufacturing Operations & Control Information

Production Schedule & Response Business Planning & Logistics Information Matching schedules & responses May be broken down into Segments Product Parameter Personnel Equipment Material Produced/Consumed Consumable Production Schedule Production Response Manufacturing Operations & Control Information

Data Flows for Batch Processes Business Planning & Logistics Information Batch Record Production Capability Production Definition Production Schedule Production Response Equipment/Asset Availability Recipes What to make, when to make it Manufacturing Operations & Control Information

Enterprise - Control Domain Boundary Functions Outside the Control Domain Information Flows of interest (e.g. Production Scheduling) (e.g. Production Schedule and Production Results) Enterprise/Control System Boundary Functions detailed Functions not detailed Functions Within the Control Domain Data flows detailed Data flows not detailed (e.g. Equipment Monitoring) ISA-95.00.01 Figure 2

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

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 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

Sample Object Model and Attributes ISA-95.00.01 Equipment model ISA-95.00.02 Equipment Attributes It is important that your audience understand what this spec will DO for their plant

Production Schedule Production Schedule ID Start & End Time Production Request Segment Requirement Parameter Personnel Requirement Equipment Requirement Material Produced Requirement Material Consumed Requirement Consumable Expected Requirement Production Schedule Is made up of 1..n Product Production Rule May Correspond to a Production Request Is made up of 1..n 0..n Product Segment or Process Segment Corresponds to a Segment Requirement Requested Segment Response May contain 0..n 0..n 0..n 0..n 0..n 0..n Production Parameter Personnel Requirement Equipment Requirement Material Produced Requirement Material Consumed Requirement Consumable Expected Is associated to either 1..n 1..n 1..n 1..n 1..n Here is the production schedule data model annotated with some of the attributes for each object. Personnel Requirement Property Equipment Requirement Property Material Produced Requirement Property Material Consumed Requirement Property Consumable Expected Property Product Parameter 0..n Corresponds to element in (see Figure 1) 0..n Corresponds to element in (see Figure 1) 0..n Corresponds to element in (see Figure 1) 0..n Corresponds to element in (see Figure 1) Personnel Model Process Parameter 1..1 Equipment Model 1..1 Material Model 1..1 1..1

Models of Manufacturing Operations ISA-95 Part 3 Models of Manufacturing Operations Recognizes that Enterprise-Control domain boundary will vary Focuses on MES functions in Level 3 Many 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

(e.g. Production Scheduling) Level 3 MES Functions Activities Inside The Enterprise Domain (e.g. Production Scheduling) Part 1 & 2 Information Flows of interest (e.g. Production Schedule) Activity detailed Activity not detailed Data flows detailed Data flows not detailed Enterprise/Control System Boundary Level 4 Activities Within Manufacturing Operations (e.g. Production Dispatching) Level 3 Part 3 Information Flows Level 2 Manufacturing Operations Process Control System Boundary

Level 3 & 4 Boundaries Vary Operations Capability Performance Schedule Definition Level 4 A Detailed Scheduling B Resource Management Tracking C Dispatching Analysis D Definition management Data Collection E Execution Level 3 Level 2 Process Control

Part 3 Manufacturing Operations Functions Product Definition Management Production Resource Management Capability Production Data Collection Execution Dispatching Tracking Performance Detailed Scheduling Schedule Level 2 Process Control Production Analysis (QA) Product This model is from Part 3 (draft). It shows the different scheduling functions in Level 3 (MES). Some of these functions could be in the enterprise if appropriate for a business.

MES Functional Categories Maintenance Production Quality Inventory Maintenance Data Collection Execution Resource Management Dispatching Tracking Performance Detailed Maintenance Scheduling Schedule Definition Requests Capability Responses Analysis Definitions Production data collection execution management resource dispatching tracking performance production Detailed scheduling schedule definition Product Analysis capability Quality definitions Quality test capability Quality test schedule Quality test performance Inventory collection data execution resource management dispatching tracking response Detailed inventory scheduling request definition analysis capability definitions X Quality test requests Detailed quality test scheduling Quality test responses Quality test resource management Quality test tracking Quality test dispatching analysis Quality definition Quality management test data Quality collection Quality test execution Level 2

MESA model provided focus for MES 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 Resource Allocation & Status Performance Analysis Document Control Product Tracking & Genealogy Dispatching Production Units Maintenance Management Labour Process Quality Data Collection Acquisition MES Supply Chain Enterprise Planning Product/ Engineering Controls Sales & Service

ISA-95 provides models for use in analysis 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 standard Yokogawa developed the B2MML XML Schemas for the World Batch Forum Yokogawa 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 Enterprise-Production Chain ERP Engineering Chain (Product Lifecycle Management) Mainte -nance ISA-95 MES Operation Procure- ment Produc- tion PCS Distri- bution Sales Supply Chain Construc -tion Field Solutions Design

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 Enterprise Resource Planning Enterprise Resource Planning Operational Excellence Applications ISA 95 Parts 1 & 2 ExaSMOC ExaSPOT ExaRQE Exaplog Exapilot VisaOAM VisaEM VisaPM VisaMB VisaPA VisaDR Reconciled Operational Information ExaOMS ISA 95 Part 3 Exaquantum/PIMS/Batch/SER PRM Process Data Historian Exaopc CS 3000, CS Batch 3000, Stardom Fieldbus and Instruments Process Control and Instrumentation

Logistics Information Manufacturing Operations & Control Information 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 Business Planning & Logistics Information Production Definition Manufacturing Operations & Control Information Capability Schedule Response

Enterprise-Control Integration Business Planning & Logistics Information Enterprise Systems (SAP, Oracle,…) B2MML Adapter (ISA-95) Production Capability Production Definition Production Schedule Production Response Manufacturing Operations & Control Information B2MML Adapter (ISA-95) Exaquantum/Batch LIMS Plant Resource Manager OPC OPC OPC Intelligent Equipment CS Batch 3000 DCSs, PLCs Intelligent Instruments

Production Response Production Response Business Planning & Logistics Information 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 Enterprise Systems (SAP, Oracle,…) B2MML Adapter (ISA-95) Production Schedule Production Response B2MML Adapter (ISA-95) Exaquantum/Batch Manufacturing Operations & Control Information

Production Capability Business Planning & Logistics Information Capability information used as input to planning & scheduling Capability = Equipment Personnel Material Available for production operations Manufacturing operations contributes asset availability data to enterprise systems Enterprise Systems (SAP, Oracle,…) B2MML Adapter (ISA-95) Production Capability B2MML Adapter (ISA-95) Exaquantum/Batch Manufacturing Operations & Control Information Capacity Production Capacity 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

Enterprise requirements drive data flow direction & content Product Definition Business Planning & Logistics Information Product 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 Enterprise Systems (SAP, Oracle,…) B2MML Adapter (ISA-95) Production Definition B2MML Adapter (ISA-95) Exaquantum/Batch Manufacturing Operations & Control Information Enterprise requirements drive data flow direction & content

Benefit of B2MML Decouples Enterprise & Control systems Vendor neutral Fewer dependencies increases robustness Vendor neutral Standards based Enables common data format when multiple manufacturing sites are integrated Common industry approach Arla Foods Nestle Proctor & Gamble Defacto standard among end-users for ISA-95 implementations Exaquantum/Batch Enterprise Systems (SAP, Oracle,…) Manufacturing Operations & Control Information Business Planning & Logistics Information Production Schedule Response B2MML Adapter (ISA-95)

Part 3 is still under development. 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

Production Operations Support definition management Definition Production resource management capability Production data collection execution dispatching tracking Performance Detailed production scheduling schedule Level 2 Process Control Exaquantum/Batch 3rd Party Scheduling Packages Production analysis (QA) Product CS Batch 3000 This model is from Part 3 (draft). It shows the different scheduling functions in Level 3 (MES). Some of these functions could be in the enterprise if appropriate for a business. Advanced Operation Assistance CS Batch 3000 Smart Field Instruments Network Solutions

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 data When ISA-95 Production Operations standard is completed B2MML will be expanded to support maintenance data

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 data When ISA-95 Maintenance Operations standard is completed B2MML will be expanded to support maintenance data Maintenance resource management Capability analysis data collection execution dispatching tracking Response Detailed scheduling Request Level 2 Process Control definition Definition This model is from Part 3 (draft). It shows the different scheduling functions in Level 3 (MES). Some of these functions could be in the enterprise if appropriate for a business.

Quality Performance Analysis 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 data When ISA-95 Quality Operations standard is completed B2MML will be expanded to support quality data Quality Test Resource Management Capability Quality Performance Analysis Data Collection Execution Dispatching Tracking Response Detailed Quality Test Scheduling Request Level 2 Process Control Definition This model is from Part 3 (draft). It shows the different scheduling functions in Level 3 (MES). Some of these functions could be in the enterprise if appropriate for a business.

Inventory Operations Inventory operations centered around Warehouse Management Systems and ERP material management Custom integration of inventory systems OPC is the preferred transport for inventory data When ISA-95 Inventory Operations standard is completed B2MML will be expanded to support inventory data Inventory Resource Management Capability Inventory Analysis Inventory Data Collection Execution Dispatching Tracking Response Detailed Inventory Scheduling Request Level 2 Process Control Definition This model is from Part 3 (draft). It shows the different scheduling functions in Level 3 (MES). Some of these functions could be in the enterprise if appropriate for a business.

Yokogawa believe ISA-95 is a valuable standard for the industry Summary Yokogawa believe ISA-95 is a valuable standard for the industry We are committed to continuing to support its development and adoption ISA-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