“how process industries stand -...

1© ARC Advisory Group

“How Process Industries Stand to benefit from seeking ISA 95

frameworks incorporated in Your RFPs”

Eighth ARC India Forum, Hyderabad July 2010

“Achieving Business Excellence through IT and Automation Solutions”

Satya SahuMESA India Member

[email protected]

Photograph of Speaker

Kamal AjitsariaMESA India Member

[email protected]


Agenda

Evolution and Introduction to ANSI/ISA-95 (S95) Standard

Benefits by incorporating S95 standards in RFPs


Agenda

Evolution and Introduction to ANSI/ISA-95 (S95) Standard

Maintenancedata

collection

Maintenenceexecution

Maintenenceresource

management

Maintenancedispatching

Maintenancetracking

Maintenanceresponse

Detailedmaintenancescheduling

Maintenancerequest

Maintenencedefinition

management

Level 1-2 Equipment

MaintenancePerformance

analysis

Maintenancecapability

Maintenancedefinition

Inventorydata

collection

Inventoryexecution

Inventoryresource

management

Inventorydispatching

Inventorytracking

Inventoryresponse

Detailedinventory

scheduling

Inventoryrequest

Inventorydefinition

management

Level 2 Equipment

inventoryPerformance

analysis

Inventorycapability

Inventorydefinition

Productiondata

collection

Productionexecution

Productionresource

management

Productiondispatching

Productiontracking

Productionperformance

Detailedproductionscheduling

Productionschedule

Productdefinition

management

Level 2 Process Control

ProductionPerformance

analysis

Productioncapability

Productdefinition

Quality testdata

collection

Quality testexecution

Quality testresource

management

Quality testdispatching

Quality testtracking

Quality testresponse

DetailedQuality testscheduling

Quality testrequest

Qualitydefinition

management

Level 1-2 Equipment

QualityPerformance

analysis

Quality testcapability

Quality testdefinition


Special Thanks to

Arne Svendsen, Director, Arla Foods, Manufacturing Services & Automation

Dave Emerson, Member of ISA-95 and Author of B2MML

Charlie Gifford, Chief Manufacturing Consultant, 21st Century Manufacturing Solutions


Topics

What is the current situation?

ISA-95 Overview

B2MML Overview

Best Practices of B2MML Extension

Customer Success Story


Agenda

What is the Current Situation?


Manufacturing System Separation

What’s happening during every shift? Material availability and consumption Capacity availability and utilization Schedule changes Product genealogy tracking and QM

What’s happening at each line? Cycle times and operating efficiencies Machine breakdowns and unplanned

downtime Quality index Predictive maintenance requirements

How are we hitting our targets? Total cost of production and variance Labor and resource productivity Order fill rates and cycle times Fixed and variable asset utilization

ERP

MOM: Manufacturing Operation Management

SFAC – Shop floor automation and control systems

DCS – Distributed control systems

MOM

SFAC

?

?

?

DISCONNECT

DISCONNECT

DISCONNECT

DISCONNECT


What is the reality of B2M Synchronization?A Manufacturing Execution Perspective

The ERP system is the leading system for

production planning,

initiating the manufacturing execution and

cost control via production orders

MES System execute the manufacturing processes

Current practices to Integrate ERP with MES

Homegrown “Non-Standardized” Interfaces

Cost Intensive to development and Maintain

No Visibility for monitoring Control


Supporting Standards

Moving to Interoperability

Supplier

App

App

App

App

ERPC

usto

m

In

teg

rati

on

Non-Standard

ERP

Supplier

App

App

Interoperability


What ISA-95 Offers

Framework for integration projects

Where business processes is separated from manufacturing processes

Focus on functions, not systems, organizations or individuals


Some End Users of the ISA-95 Standard

Energy• ExxonMobil, Inc

• Kuwait National Petroleum Company

• ExxonMobil Neftegas Limited

• BP

• British Gas

• Caspian Pipeline Consortium

• U.S. Department of Energy

• GasOil Resources LLC

• Sakhalin Energy

• Westinghouse Savannah River

Discrete Manufacturing• Advanced Micro Devices

• JDS Uniphase

• Computer Sciences Corporation

• GE Lighting

• GE Aircraft Engines

• Lucent

• Alcatel

• Cummins

Other• International Paper

Life Sciences• Eli Lilly and Co.

• Merck

• Genentech

• Roche Diagnostics

• TEVA

Food and Beverage• Nestle

• Coca-Cola North America

• Arla Foods

• United Biscuits Verkade Zaandam

• Van Dijk Food Products Zeewolde

• Cerveceria Polar

• GumLink

• SAB Miller

• Frito-Lay

• Red Gold Tomatoes

Consumer Goods• P&G

• British American Tobacco

Chemical• DOW Chemical

• Dupont

• SABIC (Saudi Arabia)

• Polaroid


ISA-95 a Manufacturing Standard

Original work focused on production of manufacturing plants

Expanded to

• Maintenance

• Inventory

• Quality Data

Defines models andterminology

Independent of data exchangetechnology


Functions in Domains

Procurement

(5.0)

Production

Scheduling(2.0)

Material and

Energy Control(4.0)

Product

Inventory Control(7.0)

Product Cost

Accounting(8.0)

Quality

Assurance(6.0)

Research

Developmentand Engineering

Product

Shipping Admin(9.0)

Order

Processing(1.0)

Marketing

& Sales

Production

Control(3.0)

Maintenance

Management(10.0)

Pack Out Schedule

Finished Goods Inventory

Finished G

oods W

aiverProcess Data

Short Term Material

and Energy Requirements

Material and Energy

Inventory

Production Capability

Production From Plan

Schedule

Incoming material and

energy receipt

Pro

duct

ion

Cos

t

Obj

ective

s

Pro

duct

ion

Per

form

ance

and

cost

Con

firm

to s

hip

Rele

ase t

o s

hip

QA

Results

Pro

duct

and

Pro

cess

Req

uire

ments

Standards and

Customer

Requirements

Standards and Customer

Requirements

In Process Waiver

Request

Process Data

QA Results

Pro

duct a

nd P

rocess K

now

How

Pro

duct a

nd P

rocess T

echnic

al F

eedback

Main

tena

nce S

tanda

rds

and

Meth

ods

Main

tena

nce T

echnic

al

Feedb

ack

Maintenance

Purchase Order

Requirements

Mate

rial a

nd

Energ

y O

rde

r

Req

uire

ments

Incom

ing

Ord

er

Con

firmatio

n

Long T

erm

M

ate

rial and

energ

yre

quirem

ents

Production O

rders

Availa

bility

Pro

duct a

nd P

rocess In

form

atio

n R

equest

Main

tena

nce R

equests

Main

tena

nce R

esp

onses

Enterprise/

Control

Boundary


System Separation & the Industry Standards

Level 4

Level 1

Level 2

Level 3

Business Planning

& LogisticsPlant Production Scheduling,Operational Management, etc

Manufacturing

Operations ManagementDispatching Production, Detailed Production

Scheduling, Reliability Assurance, ...

Batch

Control

Discrete

ControlContinuous

Control

Manufacturing Operations

(MES, LIMS, QM, AM,…)

Business Logistics

Systems (ERP)

Automation Systems

(DCS, PLC, OCS, …)

Interface defined

in ISA95.01 and ISA95.02 &

B2MML

Area addressed

ISA-95 Parts 3 & 4


ResourceInformation

(Personnel, Equipment,

Material,Segments)

Exchanged Level 3-4 Information

Manufacturing operations &control information

Production operations, maintenance

operations, quality operations, etc

Business planning &logistics informationPlant production scheduling,operational management, etc

Productdefinition

information(What must bedefined to make

a product)


information(What resources

are available)

Productionschedule

information(What to

make and use)

Productionresponse

information(What was

made and used)


Production Schedule

People

Materials

Equipment

Segments Product

Definitions

Production

Schedule


How it’s mapped to actual data exchange?

ISA-95 Models Direction Scenario

Production Schedule ERP -> MES - Process Order Download

- Production Order Download

- Control Receipe Download

- Planned Order Download

Production

Performance

MES -> ERP - Process Order Confirmation

- Production Order Confirmation

- Repetitive Manufacturing Confirmation

Product Definition ERP -> MES - BOM Download

- Routing Download

Maintenance ERP -> MES - Maintenance Order Download

MES -> ERP - Maintenance Order Create

- Maintenance Notification Create

Material ERP -> MES - Batch Download

MES -> ERP - Batch Create

- Batch Change

Equipment ERP -> MES - Workcenter Download


ISA-95 Part 3

Manufacturing Operations Management


ISA-95 Part 3 – Defines Level 3 Activities

Batch

Control

Continuous

Control

Discrete

Control

Business Planning

& Logistics

Manufacturing

Operations Management

Batch

Control

Continuous

Control

Discrete

Control

Business Planning

& Logistics

Manufacturing

Operations Management

Datacollection

Executionmanagement

Resourcemanagement

Dispatching

Tracking

Operationsresponse

Detailedscheduling

Operationsrequest

Definitionmanagement

Analysis

Operationscapability

Operationsdefinition

parameters andprocedures

Processspecific data

responsescommands

Datacollection

Executionmanagement

Resourcemanagement

Dispatching

Tracking

Operationsresponse

Detailedscheduling

Operationsrequest


Analysis


Operationsdefinition

parameters andprocedures

Processspecific data

responsescommands

Production

Maintenance

Inventory

Quality

Materials

Purchasing

Product

Development

Operations

Planning

Asset

Management

Order

Management

Distribution

& Logistics

Information PipelineCustomer

Service

Raw

Material

Storage &

Transport

Unit

Processing

Intermediate

Storage

Storage &

Transport

Unit

Processing

Product PipelineDistribution

MOM = Manufacturing Operations Management


Datacollection

Executionmanagement

Resourcemanagement

Dispatching

Tracking

Operationsresponse

Detailedscheduling

Operationsrequest


Analysis


Operationsdefinitions

ISA-95 Part 3 Generic Model

Apply to:

Production

Maintenance

Inventory

Quality Data


ISA-95 Part 3 Operation Models

InventoryDefinition

Inventory OperationsQuality Operations

Testcommands

Testresponses

Quality TestData

CollectionQuality TestExecution

Management

Quality TestResource

Management

Quality TestDispatching

Quality TestTracking

Quality testPerformance

DetailedQuality TestScheduling

Quality testSchedule

Quality TestDefinition

Management

Quality Test Level 1-2 Functions

Quality TestPerformance

Analysis

Quality testCapability

Quality testDefinition

Qualityparameters and

procedures

Qualityspecific data

MaintenanceDefinition

Maintenancecommands and

procedures

Maintenanceresults

MaintenanceData

CollectionMaintenanceExecution

Management

MaintenanceResource

ManagementMaintenanceDispatching

MaintenanceTracking


DetailedMaintenanceScheduling

MaintenanceSchedule

MaintenanceDefinition

Management

Maintenance Level 1-2 Functions


Analysis

MaintenanceCapability

Equipment specific maintenance procedures

Equipmentstate of

health data

Maintenance Operations

Inventorycommands

Inventoryreplies

InventoryData

CollectionInventoryExecution

Management

InventoryResource

Management

InventoryDispatching

InventoryTracking

InventoryPerformance

DetailedInventoryScheduling

InventorySchedule

InventoryDefinition

Management

Inventory Level 1-2 Functions

InventoryPerformance

Analysis

InventoryCapability

Inventorystorage definitions

Inventoryspecific data


ProductionSchedule

ProductionCapability

ProductDefinition

Operationalcommands

Operationalresponses

ProductionData

CollectionProductionExecution

Management

ProductionResource

Management

ProductionDispatching

ProductionTracking

DetailedProductionScheduling

ProductDefinition

Management

Production Level 1-2 Functions


Analysis

Equipment and processspecific production rules

Equipment andprocess specific data

Production Operations


B2MMLBusiness To Manufacturing Markup

Language


What Is B2MML?

B2MML = Business To Manufacturing Markup Language

Standards based, vendor independent XML schema implementation of ISA-95

• B2MML follows the functional lead of the ISA-95 standard

• Emerging as the preferred integration method, Especially for companies integrating MES to SAP systems

Tool for bringing together automation& IT groups

• Information familiar to automationprofessionals in an IT acceptable format

Logical progression when ISA-95standard used for analysis and design

Developed by and available from the WBF

• www.wbf.org

ISA-95/B2MML


B2MML XML Schemas

Common Schema

Confirm BOD

SchemaExtensions Schema

Transaction Profile

Schema

Core Components

Schema

Production Schedule

Schema Material Schema

Production Response

SchemaEquipment Schema

Product Definition

SchemaMaintenance Schema


Schema

Process Segment

SchemaPersonnel Schema


Best Practices of B2MML Schema Extension


Why it’s required?

ISA-95 Provides a framework for Shopfloor-Topfloor Integration projects

• Hence, not all data elements are part of interface structure

B2MML Provides “Flexible extension” mechanism for extension


Extension Methods

Properties

• Define properties in ID-Value combination, where available to avoid requiring schema extensions

“Any” Field

Extension Method

• New extension method introduced in v0300

• Allows for XML validation of extended schemas

• Recommended method for extensions


Properties

Intention of ISA-95 committee is to use property values to handle data not supported as object attributes in the standard

This should be used in as many cases as possible

• Using properties can avoid requiring extensions in some cases

Only some objects have properties• B2MML provides properties per ISA-95• Limits use of this option


Extension Method - Import, Include, and NameSpace

B2MML CommonSchema

B2MML Production

Schedule Schema

B2MMLXML

Document

Include

Namespace Reference

B2MML Extensions

Schema

Import

Namespace Reference

Does not disturb the original Schema Structure


Arla Food’s Success Story

32© ARC Advisory Group3

2

Arla Foods: Figures & Products

Arla is one of Europe’s Leading Dairy Suppliers

65+ Production Sites across the world

7 Billion Euro annual, 17.000 employees

Cooperative business owned by DK/SE farmers

Largest producer of organic products

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803323&view=0&object=BasketImage:002fbbc8

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803323&view=2&object=BasketImage:0010ea1a

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803dc4&view=0&object=BasketImage:00108d9b

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803324&view=0&object=BasketImage:00146f11

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803324&view=0&object=BasketImage:0015624b

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803323&view=0&object=BasketImage:00107c24

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803323&view=0&object=BasketImage:00113ffe

http://80.63.32.13/scripts/inetmanc.exe?ctx=3803323&view=0&object=BasketImage:00113a3d


3

Business- and Manufacturing-IT history & key figures

Business-IT:

• 2001 – 2006: One Arla SAP roll-out.

• 2006: Outsourcing contract of all, except overall coordination –and Manufacturing-IT !

• 2008: Upgrading til SAP 6.0.

• Governance: ”ITIL”

• One Service contract

Manufacturing-IT:

•2002-03: Selling ”Production-IT” into the Arla business

•2004: Choosing MES vendor

•2004: 1st B2MML go-live.

•2009: Team of 35 supporting 30+ sites in Arla DK, SE. Production 40.000 man hours.

•Budget < 5% of Global IT !

•Governance: Agile model

•Sourcing: Local- language integrators used per country.


Manufacturing IT answer to business requirements:

The “history”: Arla evolved from mergers & acquisitions and therefore has a highly heterogeneous manufacturing environment on the plant floor.

To solve the challenge of incoming Business requirements and the “history”, an Integrated Manufacturing Strategy has been decided:

A SAP template, including all Logistics modules (QM, PP-PI ..) is under roll-out.

A Global standard MES platform is under roll-out.

A strategy to integrate ERP-data with plant-floor data has been developed.


5

B2MML because .. of IT cost cutting

Arne Svendsen Copyright © 2004 World Batch Forum Slide 7

Scenario 1: Suppliers proprietary

solutions

B2MML because..

PI-PCS ……

SAP Business Connector / XML

MESSystem X

Plant A,B,C ..

MESSystem Y

Plant M,N,..

MESSystem ..

Plant ..

S95/WBF standard

(B2MML XML)

PLC PCS

Scenario 2: Open standard

SAP R/3

MM – PP-PI – QM

PLCPLC PLC

SAP R/3

MM – PP-PI – QM

MES/PCSPlant X

MES/PCSPlant Y

MES/PCSPlant ..

PI-PCS ……


Typical

Legacy

system

M = Manual interface

SAPfunctionality

Production Operations: ”Legacy apps”


Equipment and processspecific data

Productiondata

collection

Productionexecution

management

Productionresource

management


Productiontracking



Productionschedule

Productdefinition

management

Production level 1-2 functions

Productionanalysis


Productdefinition


Operationalcommands


M M

MM M

M


Arla

Global MES

Solution

M = Manual interface

SI = Standard interface

Production Operations: Large-site solution


Equipment and processspecific data

Productiondata

collection

Productionexecution

management

Productionresource

management


Productiontracking



Productionschedule

Productdefinition

management

Production level 1-2 functions

Productionanalysis


Productdefinition


Operationalcommands


SI

SISI

SI

SISISI

SISI


The Integrated Manufacturing solution map..

Order dispatching

PROCESS PACKAGINGRaw Matl. Fin. Goods

Process Control / Machine Control

Print

Scan

RFID

APO SAP

PP-PI QM PMNetWeaver / XI

Product Definition,

Formula Management

APO SAP

PP-PI QM PMNetWeaver / XI

Downtime,

OEE

Traceability

Matl. Tracking. Maintenance data acq

Energy & Envir. data

Enterprise integrationS95/ B2MML

PROCESS PACKAGINGRaw Matl. Fin. Goods

Process Control / Machine Control

Print

Scan

RFID

Rich HMIProduction Execution

Equipment ModelEquipment Model

Plant

Database

Product Quality

(QA / QC / SPC)

Process Analysis,

PAT

Arla

Intranet

(EP)

xMII Central Instance

Plant Reports

xMII

xMII

xMII

Site

server

SAP xMII for S95 B2M integration


9

The costs ?

2003-2006 2007 2008

Specification

R/3 -config

MES-config

Testing +go-live

24x7

XI-config

24x7

Specification

R/3 -config

MES-config

Testing +go-live

24x7

xMII-config

24x7R/3 -config

MES-config

Testing +go-live

24x7

xMII-config

24x7

Specification


Agenda

Benefits by incorporating S95 standards in RFPs


Incorporating S95 Standards in RFP

Functional Scope of L3 MOM vis-à-vis out of scope in L4 and L1 & L2

Procurement

(5.0)

Production

Scheduling(2.0)

Material and

Energy Control(4.0)

Product

Inventory Control(7.0)

Product Cost

Accounting(8.0)

Quality

Assurance(6.0)

Research

Developmentand Engineering

Product

Shipping Admin(9.0)

Order

Processing(1.0)

Marketing

& Sales

Production

Control(3.0)

Maintenance

Management(10.0)

Pack Out Schedule

Finished Goods Inventory

Finished G

oods W

aiverProcess Data

Short Term Material

and Energy Requirements

Material and Energy

Inventory


Production From Plan

Schedule

Incoming material and

energy receipt

Pro

duct

ion

Cos

t

Obj

ective

s

Pro

duct

ion

Per

form

ance

and

cost

Con

firm

to s

hip

Rele

ase t

o s

hip

QA

Results

Pro

duct

and

Pro

cess

Req

uire

ments

Standards and

Customer

Requirements

Standards and Customer

Requirements

In Process Waiver

Request

Process Data

QA Results

Pro

duct a

nd P

rocess K

now

How

Pro

duct a

nd P

rocess T

echnic

al F

eedback

Main

tena

nce S

tanda

rds

and

Meth

ods

Main

tena

nce T

echnic

al

Feedb

ack

Maintenance

Purchase Order

Requirements

Mate

rial a

nd

Energ

y O

rder

Require

ments

Incom

ing

Ord

er

Confirm

atio

n

Long T

erm

M

ate

rial and

energ

yre

quirem

ents

Production O

rders

Availa

bility

Pro

duct a

nd P

rocess In

form

atio

n R

equest

Main

tena

nce R

equests

Main

tena

nce R

esp

onses

Business case based on criticality for

• Plant Efficiency• Quality• Reliability• Compliance

• ISA-95 Part 3 diagrams is spot-on to visualize solution road maps for production management

• Eye-opener to see similar patterns across production, maintenance, quality & inventory. Help selling IT road maps in to the business

L3 MOM functionalities using S95 Part 3 Activity Models

Arla Foods experience


Incorporating S95 Standards in RFP

Integration Scope: What needs to be exchanged between L3 MOM and L4 systems such as PLM and ERP

Architectural considerations such as B2MML

• What was made

• How much was made

• What was used

• What were the wastes

• What to make

• When to make

• How to make

• What to use

PP MM QM PM

• Production Schedule

• BOR

• BOO

• Production

Confirmation

• Key Metrics

• Resource utilizations

• M-BOM

• Store RM Inventory

• WIP Inventory

• Floor FG Inventory

• Store FG Inventory

• Quality Specs

Definitions

• Inspection Schedules

• Inspection Data

• QI Notif ications

• Deviations and CAPA

• Work center

Availability

• Maintenance

Schedules

• Maintenance Orders

and Requests

• Energy and MRO

Consumptions

Production Scheduling

Inventory Management

Quality Management

Maintenance Management

• Open standards based, vendor

independent XML schemas based

on ISA-95

• Enables integration project teams

to use ISA-95 during analysis &

design then use XML during

implementation


Top5 Reasons for Incorporating S95 in RFP

Accurate & Comprehensive articulation of functional scope

Ensure selected products are S95 compliant

Reducing buffering in service quote due to scope uncertainty

Better comparison of solution and costs from various vendors

Hit the ground running towards building a scalable and interoperable system


Agenda

Thanks!!!

“how process industries stand -...

Documents