Beyond Production with ISA 95B 2 MML Jean
Beyond Production with ISA 95/B 2 MML Jean Vieille conseil www. ccm-web. com jean. vieille@isa-france. org +33 611 625 261 20/07/2004 1
Presenter n Experience l Process control, Production/ERP integration, Finite capacity scheduling, MES, LIMS, historians. l Industries: Pulp & paper, textile, wood, metallurgy, chemical, pharmaceutical, food & beverage, electronics… l Consulting with final users, solution providers, integrators and academics n Technical awareness, volunteer organizations l Member of ISA SP 88 Batch Control Systems and SP 95 Enterprise-Control System Integration, l ISA District 12 Vice president 2003 -2004 ISA France section 2000 -2001 president, l Member of APICS, World Batch Forum “Flow Analysis” WG chair, French Batch Forum founder ISA 88 overview © 2004 Jean Vieille Conseil 2
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 3
ISA 95 start n The story started from SP 88 l ISA 88 had to reduce its wide initial scope l SP 95 started at ISA 88 part one completion n Initially focused on l Process industry : SP 88 members background) l Production only : maintenance and quality not considered as specific activities n Part 1 issued in 2000 l Data models n Part 2 issued in 2001 l Adding attributes on part 1 models l Part 1 and 2 should have been merged in IEC/ISO 62264, but have been kept separated for consistency with SP 95 work n B 2 MML first draft issued in 2000, V 02 09/2003 l compliant with part 1/2 ISA 88 overview © 2004 Jean Vieille Conseil 4
ISA 95 Part 3 spontaneous generation n What’s inside the manufacturing / execution domain was unclear l Needed to define more clearly the MES / Control system fuzzy area n Part 3 defined first a production operation management functional model n Maintenance and quality appeared to be manufacturing operation categories (MOC) on their own, then inventory, then… l Inbound logistics, Outbound logistics l Internal transfers, Inventory checks l Cleaning l Tooling l Cafeteria, Fire dpt, Infirmary… ISA 88 overview © 2004 Jean Vieille Conseil 5
Part 3 multi-MOC functional model Maintenance definitions Maintenance capability Maintenance request Maintenance response Production Product definition Production capability X Production resource management Maintenance tracking Maintenance data collection Maintenance execution Quality definitions Quality test capability Quality test request Production tracking Quality test resource management Production performance analysis Production data collection Product definition management Inventory Quality test response Inventory definitions Inventory capability Inventory response Quality test data collection Inventory tracking Inventory dispatching Quality analysis Quality test dispatching Quality test execution Production execution Inventory resource management Quality test tracking Quality definition management Inventory request Detailed inventory scheduling Detailed quality test scheduling Production dispatching Maintenance analysis Maintenance dispatching Maintenance definition management Production performance Detailed production scheduling Detailed maintenance scheduling Maintenance resource management Production schedule Quality Inventory analysis Inventory data collection Inventory definition management Inventory execution Level 2 ISA 88 overview © 2004 Jean Vieille Conseil 6
ISA 95 Part 3 status n Part 3 tri-dimensional model proposes l a generic model for executing any kind of “Work” l applying to each manufacturing operation management category l Implying shared functions between manufacturing operation categories l Including shared supporting functions n Part 3 is already remarkably adopted before being published l A consistent framework for MES URS n Draft 17 June 2004 ISA 88 overview © 2004 Jean Vieille Conseil 7
ISA 95 next items n Part 4: data model extensions l Not formally decided n Part 5: Transactions l First draft available ISA 88 overview © 2004 Jean Vieille Conseil 8
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 9
Part 1/2 and B 2 MML no longer consistent, hardly relevant n Part 1/2 models are « production » flavoured n They include maintenance activity as an appendix of equipment model l Simplistic model l Inconsistent with part 3 n Part 1 / 2 not addressing actual integration needs l Business / Execution integration needs go beyond production restricted information l They do not handle other manufacturing operation categories • Inventory ISA 88 overview © 2004 Jean Vieille Conseil 10
Part 3 acknowledge Part 1 data model extensions Schedule/Request information Production Maintenance Quality Test schedule Performance/Response information Inventory schedule Production Maintenance Quality test Inventory performance response Manufacturing operations Production operations management Maintenance operations management Product Maintenance Quality test Inventory definition information Definition information ISA 88 overview Quality operations management Inventory operations management Production Maintenance Quality Test Inventory capability Capability information © 2004 Jean Vieille Conseil 11
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 12
Tentative generic ISA 95 data models n Part 1 / 2 models were developped by only considering production issue n However, l they are very flexible l Resource models are generic be essence • Firemen and operators just have different skills l Any work is driven by schedule • Taking care of exceptions (equipment breakdown, urgent order, fire in a fool reactor…) l Any work has to follow rules and specific instructions and procedures • Proceeding with an analysis, making a batch, sharpening a tool ISA 88 overview © 2004 Jean Vieille Conseil 13
Proposed part 1 revision n Define a generic data model l Based on the current production related data model l Providing a set of standard generic, MOC independent attributes n Apply this model to the for manufacturing operation categories defined in part 3 as examples l Production, Maintenance, Quality, Inventory l Providing a set of standard MOC specific attributes l Provide guidances for consistent and compliant usage of the models n Join part 1 & 2 n Each work element is MOC stamped n MOCs can be potentially mixed: l A work schedule may contain production, inventory, and quality process segments n Align B 2 MML on this new ontology ISA 88 overview © 2004 Jean Vieille Conseil 14
Proposed generalized Terminology n Process = Process n Product = Work n Production = Working n Material consummed = Material In n Material produced Material out ISA 88 overview = © 2004 Jean Vieille Conseil 15
Resource models: unchanged n Personnel, Material, Equipment are essentially independent of the operation categories n Maintenance wart on equipment model is deprecated < May be made up of 0. . n Equipment Class 0. . n Defined by < ◄ Is against 1. . 1 Equipment Has properties of > Has values for > 0. . n May result in > 0. . 1 0. . n Is made against < Maintenance Work Order 1. . 1 Equipment Class Property Maps to 1. . n Equipment Property 0. . n May be generated for > Maintenance Response 0. . n ISA 88 overview 0. . n 1. . 1 Is tested by a > Maintenance Request Equipment Capability Test Specification 0. . n Records the execution of > Defines a procedure for obtaining a > Equipment Capability Test Result © 2004 Jean Vieille Conseil 16
Process segment: unchanged n A type of consolidated resource n Stays unchanged, implying modularized « processing requirement » for any kind of work 0. . n May be made up of Process Segment 0. . n has an execution dependency on 0. . n Process Segment Dependency is a collection of 0. . n Personnel Segment Specification Has properties of 0. . n Personnel Segment Specification Property 0. . n Corresponds to element in 1. . 1 Personnel Model ISA 88 overview 0. . n Equipment Segment Specification Has properties of 0. . n Equipment Segment Specification Property 0. . n Corresponds to element in 1. . 1 Equipment Model 0. . n Material Segment Specification Process Segment Parameter Has properties of 0. . n Material Segment Specification Property 0. . n Corresponds to element in 1. . 1 Material Model © 2004 Jean Vieille Conseil 17
Process segment capability: unchanged n Stays Process Segment Capability, implying modularized « processing capability » for any kind of work Process Segment Capability Process Segment Corresponds to Is a collection of 0. . n Personnel Segment Capability Has properties of 0. . n Personnel Segment Capability Property 0. . n Corresponds to element in 1. . 1 Personnel Model ISA 88 overview 0. . n Equipment Segment Capability Has properties of 0. . n Equipment Segment Capability Property 0. . n Corresponds to element in 1. . 1 Equipment Model Material Segment Capability Has properties of 0. . n Material Segment Capability Property 0. . n Corresponds to element in 1. . 1 Material Model © 2004 Jean Vieille Conseil 18
Production Capability => Work Capability n Production changed by « Working » Production Capability 1 0. . n Is a collection of 0. . n Personnel Capability Has properties 1 of 0. . n Personnel Capability Property Equipment Capability Has properties 1 of 0. . n Equipment Capability Property 0. . n Corresponds to element in 1. . 1 ISA 88 overview Equipment Model 0. . n Material Capability 1 Is a collection of 1 0. . n. Corresponds to element in Personnel Model Working Capability Process Segment Capability Has properties of 0. . n Material Capability Property 0. . n Corresponds to element in 1. . 1 Material Model 0. . n Personnel Capability Has properties 1 of 0. . n Personnel Capability Property 0. . n Equipment Capability Has properties 1 of 0. . n Equipment Capability Property 0. . n. Corresponds to element in 0. . n Corresponds to element in 1. . 1 Personnel Model 0. . n Material Capability 1 Process Segment Capability Has properties of 0. . n Material Capability Property 0. . n Corresponds to element in 1. . 1 Equipment Model Material Model © 2004 Jean Vieille Conseil 19
Product definition: clarification needed Has a reference to > Has a reference to < n Need of complex relationships with BOR, BOM, Product production rules to be challenged Bill of Resources (External) Has a reference to > Product Definition Has associated > associated Has associated > May be 1. . n 0. . n made up of Product has an execution dependency on 0. . n Segment 0. . n Product Segment Dependency Production Rule (External) Has associated > ds on sp rre Co o t 1. . n 0. . n Process Segment Manufacturing Bill 1. . 1 Is a collection of 0. . n Product Parameter 0. . n Personnel Specification Property 0. . n Equipment Specification Property 1. . 1 Personnel Model 1. . 1 Equipment Model 1. . n Material Specification 0. . n Material Specification Property 0. . n Corresponds to element in ISA 88 overview Bill of Material (External) 0. . n Corresponds to element in 1. . 1 Material Model © 2004 Jean Vieille Conseil 20
Becomes Work definition n Potential links with other business related entities as optionnal attributes l BOM l BOR l PPR l Manufacturing bill Work Definition Has associated May be 1. . n 0. . n made up of Work has an execution dependency on 0. . n Segment 0. . n Work Segment Dependency As they are in B 2 MML n Or have a production definition derived from the generic Work definition model s rre o C o t 1. . n 0. . n Process Segment Is a collection of 0. . n Work Parameter 0. . n Personnel Specification Property 0. . n Equipment Specification Property Material Specification Personnel Model 1. . 1 Equipment Model 0. . n Material Specification Property 0. . n Corresponds to element in 1. . 1 ISA 88 overview ds n po 0. . n Corresponds to element in 1. . 1 Material Model © 2004 Jean Vieille Conseil 21
Production schedule => Production Schedule Is made up of 1. . n Production Rule Corresponds to a < Production Request Is made up of 0. . n 1. . n Process or Product Segment Corresponds to a < Requested Segment Response Segment Requirement May contain 0. . n Production Parameter Personnel Requirement 0. . n Equipment Requirement 0. . n Material Produced Requirement 0. . n Material Consumed Requirement Consumable Expected Is associated to either > 1. . n Product Process Parameter ISA 88 overview Personnel Requirement Property Equipment Requirement Property Corresponds to element in Personnel Model 1. . n Material Produced Requirement Property Corresponds to element in Equipment Model Corresponds to element in Material Model 1. . n Material Consumed Requirement Property 1. . n Consumable Expected Property Corresponds to element in © 2004 Jean Vieille Conseil 22
…=> Work Schedule Working Schedule Is made up of 1. . n Corresponds to a < Work Definition Working Request Is made up of 0. . n 1. . n Process or Work Segment Corresponds to a < Requested Segment Response Segment Requirement May contain 0. . n Working Parameter Personnel Requirement 0. . n Equipment Requirement 0. . n Material Produced Requirement 0. . n Material Consumed Requirement Consumable Expected Is associated to either > 1. . n Personnel Requirement Property Work Process Parameter ISA 88 overview Equipment Requirement Property Corresponds to element in Personnel Model Corresponds to element in Equipment Model 1. . n Material Out Requirement Property Corresponds to element in Material Model 1. . n Material In Requirement Property 1. . n Consumable Expected Property Corresponds to element in © 2004 Jean Vieille Conseil 23
Production Performance => Production Performance Is made up of 1. . n Production Response Is made up of 1. . n Corresponds to a < Process Segment Response May contain 0. . n Production Data 0. . n Personnel Actual Equipment Actual 1. . n Personnel Actual Property Corresponds to element in Personnel Model ISA 88 overview 0. . n Material Produced Actual 1. . n Equipment Actual Property Corresponds to element in Equipment Model Material Produced Actual Property 0. . n Material Consumed Actual 1. . n Material Consumed Actual Property Corresponds to element in Consumable Actual 1. . n Consumable Actual Property Corresponds to element in Material Model © 2004 Jean Vieille Conseil 24
…=> Work Performance Working Performance Is made up of 1. . n Working Response Is made up of 1. . n Corresponds to a < Process Segment Response May contain 0. . n Working Data 0. . n Personnel Actual Property Corresponds to element in Personnel Model 0. . n Material Produced Actual Equipment Actual 1. . n ISA 88 overview 0. . n Material Consumed Actual 1. . n Equipment Actual Property Equipment Model Consumable Actual 1. . n Material Out Actual Property Corresponds to element in 0. . n 1. . n Material In Actual Property Corresponds to element in Consumable Actual Property Corresponds to element in Material Model © 2004 Jean Vieille Conseil 25
Model Instanciation n The models apply as is for any MOC n However, attributes depend on: l MOC specifics • Production, inventory, quality, maintenance l Transaction specifics • Intermediate or final reporting l Industry specifics (i. e Food & Beverage) • Expiration date applies for perishable goods l Solution specifics (i. e. SAP) • Reverse. Transaction l User specifics (i. e. P&G, Nestlé…) • GTIN ISA 88 overview © 2004 Jean Vieille Conseil 26
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 27
Align material resource specification and usage n Material in / out and material consummed for l Process segment capability l Working capability l Work definition / Work segment Production Schedule n As it is in l Production schedule l Production performance Is made up of 1. . n Production Request Is made up of 1. . n Segment Requirement Process Segment Capability May contain Is a collection of 0. . n Personnel Segment Capability ISA 88 overview 0. . n Equipment Segment Capability 0. . n Material Segment Capability 0. . n Production Parameter 0. . n Personnel Requirement 0. . n Equipment Requirement 0. . n Material Produced Requirement 0. . n Material Consumed Requirement 0. . n Consumable Expected © 2004 Jean Vieille Conseil 28
Process / product / Production segment recursivity n Process segment capability l in Working capability and process segment capability n Segment requirement l in production schedule (OK In B 2 MML) n Segment response l in production performance (OK In B 2 MML) Production Request Production Capability 0. . n Process Segment ISA 88 overview 0. . n Product Segment Process Segment Capability 1. . n Segment Requirement Production Response 1. . n Segment Response © 2004 Jean Vieille Conseil 29
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 30
B 2 MML n B 2 MML schemas will be easily aligned to the generalized ISA 95 part 1 models n Extension mechanisms must be improved / complemented l Properties l User defined extensions in separate files/namespaces n They shall provide l a basic set of generic referenced schemas l a serie of standard/custom extensions schemas for MOC / Transactions / Industry / Solution / User specifics l A template for generating schemas instances ISA 88 overview © 2004 Jean Vieille Conseil 31
B 2 MML n Example: Work. Schedule ISA 88 overview © 2004 Jean Vieille Conseil 32
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 33
Example: Work schedule for transfer orders n Simplifed Working schedule Working Schedule Is made up of 1. . n Working Request Is made up of 1. . n Segment Requirement May contain 0. . n Material In Requirement ISA 88 overview 0. . n Material Out Requirement © 2004 Jean Vieille Conseil 34
Example: transfer order Dispatch production run ## Transfer Schedule Transfer Request 2 nd lading mission 1 st lading mission Segment Requirement Personnel Requirement Equipment Requirement Items a, b, c (loc X 1) Material In Requirement ISA 88 overview Segment Requirement item a (QC area) Items b, c (loc Y 1) Material Out Requirement 100 kg Mat A (loc X 1) Material In Requirement 99 Kg Mat A (Loc. Y 2) 1 Kg scrap Material Out Requirement © 2004 Jean Vieille Conseil 35
Transfer transaction examples (from Nestlé) n Transfer schedule: l Storage location to Storage location n Transfer performance: l Storage location to Storage location (sollicited) l Confirm transfer l Cancel transfer l Storage location to Storage location (unsollicited) l Inbound receipt l Sublot transfer l Plant to Plant l Batch to Batch l Material status change ISA 88 overview © 2004 Jean Vieille Conseil 36
Agenda 1. ISA 95 history status and future 2. ISA 95 dicrepancies 3. Tentative generic ISA 95 data models 4. Other ISA 95 issues 5. B 2 MML 6. Application to inventory operations 7. Conclusion ISA 88 overview © 2004 Jean Vieille Conseil 37
7. Conclusion 1. MOC part 3 concept shall be introduced in part 1 1. High priority item 2. May delay part 4 and 5 2. Part 1 data models can be (very) easily generalized 1. to allow their application to any MOC 3. They need some improvements based on 1. B 2 MML development and implementation feedback 2. Generalized needs from MOC instantiation 4. Next B 2 MML release candidate 1. Can implement and validate modified generic models 2. Can be developed on the spot – Drafts already available ISA 88 overview © 2004 Jean Vieille Conseil 38
Thank You 39
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