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

2. 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

3. What is ISA-95?

4. ISA-95 is Multi-part Standard
ANSI/ISA “Enterprise - Control System Integration - Part 1: Models and Terminology”
IEC/ISO
Joint international standard
Part 2:
ANSI-ISA “Enterprise - Control System Integration - Part 2: Object Attributes”
IEC/ISO
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 is the standard and that SP95 was the committee.
Mention that this is a USA standard, under the auspices of ANSI

5. 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.

6. 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

7. 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

8. 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 Figure 3

9. 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 Figure 4

10. 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 Draft 13 Figure 3

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

12. 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

13. 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

14. 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

15. 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

16. 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 Figure 2

17. 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

18. 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

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

20. 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

21. 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.

22. 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

23. (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

24. 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

25. 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.

26. 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

27. 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

28. 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

29. Yokogawa Support for ISA-95

30. 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 ( open system architecture for asset management
Use OPC as the transport for the Open O&M content

31. 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

32. 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

33. 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

34. 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

35. 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

36. 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

37. 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 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

38. 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)

39. 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

40. 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

41. 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

42. 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.

43. 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.

44. 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.

45. 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