An ISA95 Overview: Workflow and System Modeling For 21st Century Manufacturing Flexibility

Intelligent Production Management Seminar
An ISA95 Overview:
Workflow and System Modeling for
21st Century Manufacturing Flexibility
Charlie Gifford
Solutions Architect-Lean Performance Mgt.
Global Professional Services Business
Office (208) 788-5434 Fax: (208) 788-5690
Cell (208) 309-0990 Charlie.Gifford@ge.com
© 2004 GE Fanuc Automation All rights reserved.

Seminar Overview
• Goal of the ISA95 Effort
• Collaborative Production Management (CPM)
Business Drivers
• ISA95 Direction and Scope of Plant Model
• Agreement of Control Responsibility
• Object Model
– Four categories of resources
– Four categories of information
• Part 3: Manufacturing Operations Model
• Question: What does this mean for actual
project implementation? XML - schemas
• ERP-Proficy connector
• ISA95 Status

Goals
• Understand the market drivers for ISA95
• Understand the two points of view for supply
chain optimization
• ISA95 Value and Direction
• Agreement of Control Responsibility
• Understand Object Model
• Proficy is ISA95 Compliant
• Understand ISA95 Business Value

Ever Had This Happen?
• The VP of IT announces that the ERP

installation is done, Now the only thing left to do
it tie into the plant systems!
–PS: The interface solution is trivial and was due
yesterday.
• To reduce inventory or meet your company’s
Make-To-Order strategy, you need to run very
short schedules (multiple per day) and very fast
end of production responses (immediate)!
–PS: Don’t increase inventory or staff

Goals of the 95 Effort Business
Logistics
• Integration of business (logistics)

systems to manufacturing is
hard to do Manufacturing
Operations
– Different systems, cultures,

terminology, timing...
– Benefits expected from standardization
and documentation of “best practices”

Goals of the 95 Effort Business
Logistics
• Effective operation of manufacturing is

hard to do
Manufacturing
– MES solutions are too related to Operations
processing methods and too industry-

specific
– Benefits expected from standardization
and documentation of “best practices”

Manufacturing Process Types
Drive Complex System Requirements
Production Types
Discrete Manufacturing Discrete
Batch Processing
Batch
Continuous Processing
Process
Workorder Mgt Categories
Engineer-to-Order
ETO MTO MTS
Make-to-Order
Make-to-Stock
The 9 combinations (or hybrids) of Production Type and Work Order
Management each have a different set of business rules processes
in their supply chain, enterprise and production base

“The Goal of the Industrial Enterprise*
is to make money. Make more money now and
in the Future” The 3 Basic Metrics:
(T) Throughput : *Goldratt, The Goal, page 58-62
¾The rate: the system generates money through sales

(I) Inventory (and investments) :
¾The money the system invests in things it intends to sell
(all saleable resources: material, equipment)
(OE) Operational Expenses :
¾The money the system spends to transform Inventory
into Throughput
$$$ $$$ $$$
Throughput Inventory Operational Expenses
Money coming in Money tied up inside Money going out

CPM Business Drivers
Business Processes and Metrics
Plan
Suppliers’ Customer’s
Supplier Customer
Deliver Source Make Deliver

Source Make Deliver Source Make Deliver Source
Return Return Return
Return
Supplier Your Company Customer
Internal or External Internal or External

SCOR’s Five Distinct Management Processes
Corporate approach set by optimization view
Supply Chain vs. Plant Optimization:
• 60-80% Liquid Assets are in Supply Chain
• 60-80% Tangible Assets in your Plants
© Supply-Chain Council, 2001 All rights reserved.

CPM Business Drivers Summary:
Liquid Asset Optimization
• Supply chain optimization
• Capable to promise
• Reduced cycle time
• Asset efficiency
• Agile Manufacturing
• Supply Chain & Operator Empowerment
• Improved Planning

Tangible Asset Optimization
• Increase:
–Plant Throughput
–Product quality
–Rework efficiency
–Equipment utilization
–Line uptime
–Event communication and response

Tangible Asset Optimization
• Decrease:
– Non-value-add product costs
– Plant inventory and work-in-process (WIP)
– Regulatory reporting costs
– Rework (eliminate)
– Waste: material and human resources
– Time-to-volume on a new product introduction (NPI)
– Time-to-theoretical yield and cycle time on an NPI
– Line changeover time
– Maintenance: costs, response time, and downtime
– Total cost of ownership for IT and controls systems

ISA 95 Provides Direction for Optimization
• The ANSI/ISA 95.00.01 “Enterprise - Control System
Integration - Part 1: Models and Terminology”
– Also Draft International Standard ISO/IEC 62264-1
• ANSI/ISA 95.00.02 “Enterprise - Control System Integration
- Part 2: Object Attributes”
• Draft ISA 95.00.03 “- Part 3: Activity Models of
Manufacturing Operations Management”
• Draft ISA 95.00.04 “- Part 4: Object Models and Attributes
of Manufacturing Operations Management”
• Draft ISA 95.00.05 “- Part 5: Business to Manufacturing
Transactions”

Scope
ENTERPRISE
ISA S88
Standard ISA95
SITE
Standard
AREA AREA AREA
CONTINUOUS BATCH DISCRETE

PRODUCTION PROCESS PRODUCTION
UNIT CELL LINE From ISA-95 Copyright ISA 2004.
Used with permission. www.isa.org

Scope
ENTERPRISE
ISA S88 95.01 & 95.02

Standard ISA95
SITE
Standard
95.03
AREA AREA AREA
CONTINUOUS BATCH DISCRETE

PRODUCTION PROCESS PRODUCTION
UNIT CELL LINE

ISA95.01 Levels
Level 4
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Interface addressed
in the ISA 95.01 and
Level 3 ISA 95.02 standard
Manufacturing Area addressed
Operations & Control in the ISA 95.03
Dispatching Production, Detailed Production standard
Scheduling, Reliability Assurance, ...
Levels
2,1,0
Batch Continuous Discrete
Control Control Control From ISA-95 Copyright ISA 2004.

ISA95.01 Levels
Level 4
Business Logistics
Business Planning & Logistics
Management
Interface addressed
Level 3 (ERP) in the ISA 95.01 and

ISA 95.02 standard
Manufacturing Area addressed
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
in the ISA 95.03
standard
Scheduling, Reliability Assurance, ...
Operations Management
Levels
(MES, LIMS, AM, …)
2,1,0
Batch Continuous Discrete
Control Control Control

ISA 95 Part 1 and Part 2 Exchanged
Information
Information must efficiently and effectively

cross the boundary between business
and manufacturing systems
S95 Parts 1, 2 and 3
Part 1 defines:
• standard terminology and object models
• scope of the manufacturing control domain
• functions associated with the interface between
control functions and enterprise functions
• information that is shared between
control functions and enterprise functions
Part 2 defines:
• attributes for all objects that are defined in Part 1. The objects
and attributes are used for exchange of information between
different systems and used as the basis for relational databases.
Part 3 defines:
• the functions and activities at level 3
(Production Management layer)

ISA 95 Models and Definitions
Domain Functions Functions

Definitions in Domains of Interest
Information Categories of Information

Definitions Information Flows of Interest
S95 Functional
Enterprise-Control Model
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
Order Product Cost Product

Processing Accounting Shipping Admin
(1.0) (8.0) (9.0)
Product
Production Inventory
Scheduling Control(7.0)
(2.0)
Production
Control ISA S95
Quality
Material and
(3.0)
Part 1&2 Assurance
Energy Control (6.0)
(4.0)
Maintenance
Procurement Research Marketing
Management
(5.0) Development & Sales
(10.0)
& Engineering

Identified Information Categories (Flows)
Enterprise Information
Production Product
Production Production
Capability Definition
Schedule Performance
InformationInformation (What to (What was
(What is make and made and
(How to make
available use) used)
a product)
for use)
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc From ISA-95 Copyright ISA 2004.

Agreements on the Control Responsibility
• Drawing the line between the Level 3 and the Level 4 functions
• A function is in the control domain if:
– The function is critical to:
> maintaining regulatory compliance.
» Includes such factors as safety, cGMP, and environmental compliance
> plant safety
> product quality
> plant reliability
• Why ?
– Where is the responsibility ?
– Who has the responsibility ?
– Where are firewalls needed (policy and technology) ?

dS95.03 Production Control Functions
Where is the Line of Responsibly?
Product Production Production Production
definition capability schedule performance
Detailed
production
scheduling
Production
Production
resource
tracking
management
Production
Analysis
dispatching
Product Production
definition data
management collection
Production
execution
Level 2 Process Control

Section 14: Logistics vs. Operations?
Determine Lines of Responsibility vs.
Technical Integration between Level 3 and 4
• The functions critical to Level 3:
–Product quality, Plant safety, Plant reliability
and Maintaining regulatory compliance
Maintenance Production Quality Inventory
Maintenance Maintenance Maintenance Maintenance Product Production Production Production
definitions capability request response definition capability schedule performance Quality Quality test Quality test Quality test Inventory Inventory Inventory Inventory
definitions capability request response definitions capability request response
T Detailed
maintenance
scheduling
Detailed
production
scheduling Detailed
quality test
scheduling
Detailed
inventory
scheduling
Production
Maintenance Production
Maintenance resource Inventory
resource tracking Quality Inventory
tracking management Quality test resource
R
management test resource tracking
tracking management
management
Production
Production
Maintenance Maintenance performance Inventory Inventory
dispatching Quality test Quality
dispatching analysis analysis dispatching analysis
dispatching analysis
Maintenance Maintenance Product Production Quality Inventory Inventory

Quality
definition data definition data definition data
definition test data
management collection management collection management collection
Quality test Inventory

Maintenance Production execution
execution execution execution
Level 2

4x4 Object Model Describes Data Flows
• Four categories of resources
– Personnel
– Equipment
– Material (and Energy)
– Process Segments
• Four categories of information
– Capability & Capacity Definition
– Product Definition
– Production Schedule
– Production Performance

S95 Functional
Enterprise-Control Model
From ISA-95 Copyright ISA 2004.
Order Product Cost Product
Processing Accounting Shipping Admin
(1.0) (8.0) (9.0)
Product
Production Inventory
Scheduling Control(7.0)
(2.0)
Production
Control ISA S95
Quality
Material and
(3.0)
Part 1&2 Assurance
Energy Control (6.0)
(4.0)
Maintenance
Procurement Research Marketing
Management
(5.0) Development & Sales
(10.0)
& Engineering
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org

Four Resource Object Models
Personnel resources managed for production
People
Equipment resources managed for production
Equipment
Material and Energy resources

Materials managed for production
Business view of production processes
Process Segments

Persons and Personnel Classes with
Required Properties
• The picture below represents person and
personnel class information
Supervisor Professional Laborer Operator Pump Draftsman
Engineer Mechanic
Qualification
Test
Qualification
Sally Jones- ID#12344 Joe Smith - ID#12345 Test Results

Standard Terminology For
Equipment Classification
ENTERPRISE
Level 4 activities
typically deal with
these objects SITE
AREA
Level 3
activities
typically PROCESS PRODUCTION PRODUCTION STORAGE
CELL UNIT LINE AREA
deal with
these WORK STORAGE
UNIT
objects CELL UNIT
Lower level Lower level Lower level Lower level

equipment used equipment used equipment used equipment used
in batch operations in continuous in repetitive or in inventory
operations discrete operations operations

Material Classes, Definition, Lots,
Sublots, and Properties
• Standard terminology for defining material
information
Material Class Material Definition Lot Sublot
HCl Acid HCl 50% HCL-50-100019 HCL-50-100019
Barrel 15
l l
ria ria
e e
at ss at ition
M la M in
C e f
D
pH Density Color Purity

QA Test QA Test Location
Results Specification
pH Density Color Purity

1.0 1.05 Straw 99.5%

Process Segments
• The business view of production
Raw Finished
Materials Products
Pharmaceutical Manufacturing
(3 Segments)
Make
Make Package
Active
Pills Doses
Ingredient
Inventory tracked Inventory tracked Inventory tracked

for Active Ingredient for Pills for Pill Packs
Know throughput, Know throughput, Know throughput,
resources and time to resources and time to resources and time to
make Active Ingredient make Pills make Pill Packs

Capability, Product, Schedule, and
Performance Information
What is available for use for production
Product
Time
Capability/Capacity
What is needed to make a product

Product
Definitions
What to make and resources to use

Production
Schedule
What was made and

resources actually used
Production
Performance
Production Capability Models
Product
People Time
Capabilities
Equipment What is available

- Currently
- In the future
- Per resource
Materials - Per segment of
production
- What is available
- What is unattainable
- What is committed
Segments

Production Capability & Capacity
Current Production Capacity
Production Capacity
Capacity
Unattainable Capacity
Available Capacity
Committed Capacity
Time
Current Capacities

Product Definition
• Shared information about each product between
Level 3 and 4
–References manufacturing instructions
> For Continuous may be flow sheets
> For Batch may be site or master recipes
> For Discrete may be setup or assembly instructions
–Defines all materials used by manufacturing

Product Definition
• References the Bill of Materials
• References the Bill of Resources
• Defines resources required per segment
–Equipment
–Personnel
–Material

Per Product Definitions
Scheduling Material
System System
Product Definition
Bill Of Resources Bill Of Materials
e.g. 10 Speed Bicycle e.g. 10 Speed Bicycle
Product f
f
ll O es Segments ll O als
Bi urc Bi i
er
so at
M
Re
Manufacturing
Bill
Production Rules
Frame : 1
e.g.
Wheels : 2
Frame Final
Paint 10 Speed Bicycle Chain : 1
ly b s
m
Assembly Assembly s se tion Seat : 1
A ruc
st
In Handlebars :1
Color Brake Pads : 4
Frame Seat
Manufacturing ...
Type Height System

Production Schedule
• Production Schedule
• Production Request What to make
• Segment Request - Priority and/or dates
People • Expected Produced - What to use:
Material -Materials
-Equipment
• Expected Consumed -personnel
Material - Production parameters
• Expected Personnel (e.g. Color, Options,…)
• Expected Equipment
Equipment
• Production Parameters
•…
Materials
Production
Schedule
Per location (Site, Area, …)
Per week, day,
shift, order, …
Segments

Production Performance
• Production Performance
• Production Response
• Segment Response
People • Produced Material What was made
Actual - What material was
• Consumed Material actually produced
- What materials were
Actual
actually consumed
• Personnel Actual - Equipment used
Equipment • Equipment Actual - Personnel used
• Production Data - Production data
•… (e.g. Purity, density,…)
Materials
Per location (Site, Area,

…)
Production
Segments Per shift, hour,
Performance end of batch, …

ISA95 Part 3: Activity Models of
Manufacturing Operations
Order
Processing
(1.0) Product Cost Product
Accounting Shipping Admin
(8.0) (9.0)
Production
Scheduling PRODUCTION
(2.0)
OPERATIONS
INVENTORY
Material and Production OPERATIONS Product
Energy Control Control Inventory Control
(4.0) (3.0) (7.0)
INVENTORY
OPERATIONS QUALITY
ASSURANCE
OPERATIONS
Procurement Quality
MAINTENANCE Assurance
(5.0)
OPERATIONS (6.0)
Marketing
In Development & Sales
Maintenance
Draft 17 Available Management Research
(10.0) Development
and Engineering
d95.03 Manufacturing Operations
Functions
Product Production Production Production
definition capability schedule performance
Detailed
production
scheduling
Production
Production
resource
tracking
management
Production
Analysis
dispatching
Product Production
definition data
Production
execution
Equipment and Process Operational Operational Equipment and Process
Specific Production Rules Commands Responses Specific Data
Level 2 Process Control From ISA-95 Copyright ISA 2004.


Business plan* (APICS terminology)
(Per Product Line, Per Time – Very Long Time Horizon)
Production
Demand plan* (APICS terminology)
Schedule
Flow
(Per Product, Per Time –Long Time Horizon)
1.1 Production Forecasting Activity (ISA-95.01 )
Production plan* (APICS terminology)

(Per Product, Per Time - – Long Time Horizon)
2.4 Production scheduling activity (ISA-95.01)
Production schedule – (Master production schedule - APICS terminology)

(Per Site/Area, Per Product, Per Time – Medium Time Horizon)
Detailed production scheduling activity (ISA-95.03)
Detailed production schedule

(Per Workcenter, Per Product/Intermediate, Per Time – Short Time Horizon)
Production dispatching activity (ISA-95.03)
Production Dispatch list

(Per Workcenter or Workcenter element, Per produced item, Per Time – Very Short Time Horizon)
* Not in the scope of this standard

Other Enterprise Activities in
Manufacturing Operations
• Some actives are not specific to manufacturing
• ISA-95.03 lists references to standards in these areas
Level 4
Inventory Management Management

Major Level 3 Operations of Information of Configuration
Activities
Maintenance Quality Management
Within Operations Operations of Security
Manufacturing
Production Management Management
Operations Operations of Documentation of Compliance
Level 2
Activity detailed
Activity not detailed
Activity outside scope

Question: What does this mean for actual
project implementation?
Answer: XML Schemas:
Common Language and Common Protocol

between Levels 3 and 4
B2MML - Business to Manufacturing
Markup Language
• XML-based implementation of ISA95 standard developed by
the volunteer effort of the WBF's XML Working Group
• Provides a set of XML schemas based upon the ANSI/ISA 95

family of standards. The schemas were written using the World
Wide Web Consortium’s XML Schema language (XSD)
• Used to integrate ERP and supply chain management systems
with manufacturing systems
• Formal way to document information and agreements
• NOTE: Does not define TRANSACTIONS, just the data to be

used inside other transaction systems (e.g. OAG)

B2MML: Schemas
• Common Schema
• Equipment Schema
• Material Schema
• Personnel Schema
• Process Segment Schema
• Product Definition
• Production Capability
• Production Performance
• Production Schedule
• Maintenance Schema
Why XML ?
• Openness
• Simplicity
• Self-describing
• Interoperability
• Structure
• Extensibility
• Platform independency
• X-Path – Query Language
• Self-documenting
• Fully Extensible

ERP - Proficy Connector
ERP System
XML Input Schemas B2MML

•Equipment
•Maintenance
•Material
•Process Segment
•Product Definition
•Production Capability
•Production Performance
•Production Schedule
S95 Connector
XML Standard Schema –

Transaction Table compatible
Proficy Transaction Table

S95 Business Values
• Easier Level 3 product comparison, selection, and replacement
using consistent models and language across all industries
• Enhanced protection of end users’ intellectual property through

consistent supplier product functional partitioning
• Easier flow of information from consistent messaging between

business and production systems
• Faster implementation of integration projects by enabling

industry-wide standards using current technologies
• LARGE Reduction implementation and maintenance costs for

enterprise integration through the use of single interface schema

Status
• ISA95.00.01 & ISA.95.00.02 available
• IEC/ISO 62264-1 available from IEC & ISO
• ISA 95.00.03 /.04/.05 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

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What are the goals of ISA95?

What are the goals of ISA95?

What are the different types of manufacturing processes and work order categories?

What are the different types of manufacturing processes and work order categories?

Intelligent Production Management Seminar

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

• The VP of IT announces that the ERP

© 2004 GE Fanuc Automation All rights reserved.

• Integration of business (logistics)

– Different systems, cultures,

© 2004 GE Fanuc Automation All rights reserved.

• Effective operation of manufacturing is

processing methods and too industry-

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

¾The rate: the system generates money through sales

© 2004 GE Fanuc Automation All rights reserved.

Deliver Source Make Deliver

Internal or External Internal or External

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

AREA AREA AREA

CONTINUOUS BATCH DISCRETE

© 2004 GE Fanuc Automation All rights reserved.

ISA S88 95.01 & 95.02

CONTINUOUS BATCH DISCRETE

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

Level 3 (ERP) in the ISA 95.01 and

© 2004 GE Fanuc Automation All rights reserved.

Information must efficiently and effectively

© 2004 GE Fanuc Automation All rights reserved.

Domain Functions Functions

Information Categories of Information

Order Product Cost Product

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

Level 2 Process Control

© 2004 GE Fanuc Automation All rights reserved.

Maintenance Maintenance Product Production Quality Inventory Inventory

Quality test Inventory

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org

Personnel resources managed for production

Equipment resources managed for production

Material and Energy resources

Business view of production processes

© 2004 GE Fanuc Automation All rights reserved.

© 2004 GE Fanuc Automation All rights reserved.

Lower level Lower level Lower level Lower level

© 2004 GE Fanuc Automation All rights reserved.

pH Density Color Purity