How to use ISA95 part 3 for MES functional URS Jean Vieille www.psynapses.net/vieille Copyright © 2005 World Batch Forum 1 Agenda · · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion Copyright © 2005 World Batch 2 Forum MES: between Business and Manufacturing · MES is a fuzzy area: ­ IT/Business community hardly understand actual manufacturing control constraints and needs ­ Control community doesn't catch business mind, · MES ­ Crosses business processes, business tasks and control tasks ­ Encompassed production, quality, maintenance, and inventory execution control · Not a complex technical issue ­ Compared to automation: no fancy algorithmic, multipath sequencing... · However ­ Structure requirements and assessment process takes a unique mixture of skill sets and years of study and practice Copyright © 2005 World Batch 3 Forum Example: URS vs FS in GAMP4 ??? Copyright © 2005 World Batch 4 Forum Agenda · · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion Copyright © 2005 World Batch 5 Forum PRM + ISA95-3 functional models 1.Detailed work scheduling 8. Work resource management 2. Work dispatching 7. Work definition management 3. Work execution 4. Work data collection 5. Work tracking 6. Work analysis Order Processing Product Cost Accounting Product Shipping Admin Production Scheduling Product Inventory Control Production Control Material and Energy Control Quality Assurance Procurement Maintenance Management Research Development & Engineering Marketing & Sales From ISA95 standards Copyright © 2005 World Batch 6 Forum Combined Order Processing Product Cost Accounting Product Shipping Admin Detailed work scheduling Work resource management Work tracking Production Scheduling Work dispatching Work analysis Work definition management Work data collection Work execution Detailed work scheduling Work resource management Work tracking Work dispatching Work analysis Detailed work scheduling Detailed work scheduling Work definition management Work data collection Work resource management Work tracking Work resource management Work tracking Work execution Work dispatching Work analysis Work dispatching Work analysis Work definition management Work data collection Work definition management Work data collection Work execution Work execution Detailed work scheduling Work resource management Work tracking Procurement Work definition management Work dispatching Work analysis Work data collection Research Development & Engineering Marketing & Sales Work execution Copyright © 2005 World Batch 7 Forum Beyond Production · ISA95 Part 3 defines the following Manufacturing Categories (MOCs): ­ ­ ­ ­ Production Quality tests Maintenance Inventory control Distribution, Transportation Inbound, Outbound logistics, Internal transfers Tooling Cleaning ... Operation · Other or different MOCs can be defined. Example: ­ ­ ­ ­ ­ · · It's all about execution! Advanced MES solutions take care of many aspects of product manufacturing and handling Copyright © 2005 World Batch 8 Forum The ISA95 tri-dimension functional framework Manufacturing Operation Categories Production Maintenance Quality Inventory ... Manufacturing Operation Core Activities Work Detailed Scheduling Work Dispatching Work Execution Work Data Collection Work Tracking Work Analysis Work Definition Management Work Resources Management Functional Requirements Execution/Manufacturing Business/Planning Copyright Supporting activities Management of security Management of information Management of configurations Management of documents Management of regulatory compliance Management of incidents and deviations World Batch 9 © 2005 Forum Agenda · · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion Copyright © 2005 World Batch 10 Forum 2/3Tiers Business / Execution functional hierarchy Business Tasks Business Processes (Business side) Business Tasks (Business related) Business Processes (Execution side) Business Tasks (Execution related) (S95, MES) (S88, Control) SOPs, EPEs Work instructions Execution Processes Recipes, Routings Copyright © 2005 World Batch 11 Forum URS methodology overview Manufacturing Operation Category Business Processes Activity Activity Manufacturing Operation Category Business Business Processes Processes Task Task Task Task Task Task Characterization t ne mml ev ed S RU o Application Application Component Component Application Component Solution adequacy & FS mapping Copyright © 2005 World Batch 12 Forum General process Phase 1: Technical modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro BP / Task iteration Synchro Implementation Maintenance Evolution Copyright © 2005 World Batch 13 Forum Phase (1): Technical modeling Step 1.1 Manufacturing Op. Categories Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Step 1.2 « Material » Resource Step 1.3 « Equipments » Resource Step 1.4 « Personnel » Resource Phase 4: Solution Selection Phase 5: Implementation Synchro Step 1.5 « Working » Segments Control Spec and Design Copyright © 2005 World Batch 14 Forum Phase (2): Business processes · The highest functional requirement level · They illustrate situations and tasks (functional services) activation scenarios · They can be manual, semi or fully automated · They can be hierarchic ­ High level processes activate lower level processes ­ Elementary processes are tasks... Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro · They can be compared to Manufacturing processes : ISA88 Recipes (BP) activating EPEs (tasks) Copyright © 2005 World Batch 15 Forum Business processes classification 1. Execution management ­ Work organization and execution ­ MOC specific or shared Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro 2. Resources management ­ Resources, not work related activities 3. Operations management ­ Dashboards, performance indicators, activity reports not specifically linked to work orders 4. Repository synchronization Depend on business management options Copyright © 2005 World Batch 16 Forum BPs highlight interfaces requirements · Some processes are shared ­ Between several MOCs ­ Between Business and Execution Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro · These situations indicates communication links and likely transactions. Copyright © 2005 World Batch 17 Forum BPMN language By BPMI, www.bpmi.org Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro Copyright © 2005 World Batch 18 Forum Phase (3) : Tasks Phase 2 Business processes Phase 3 Tasks Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro Step 3.1 Task list Step 3.2 Description Step 3.3 Consolidation Enterprise MES Core system Copyright © 2005 World Batch 19 Forum Tasks Characterization Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro 1. Physical level 2. Segments 3. Manufacturing Operation Categories 4. Responsibility 5. Users 6.Technical constraints 7.Dependences 8. Task style 9. Justification 10. Information Copyright © 2005 World Batch 20 Forum Tasks consolidation · Similar tasks appear in different MOCs · Consolidation may be possible Identical, separate Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro Similar, different MOC1 Common MOC2 Copyright © 2005 World Batch 21 Forum Phase 4: Solution selection Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro Step 4.1 Pre-qualification Long list Middle list Short list Consolidated Tasks (phase 3) Step 4.2 Functional adequacy Step 4.3 Mock up Step 4.3 Select and order Copyright © 2005 World Batch 22 Forum Functional adequacy Information Technical constraints Manufacturing Operation MOC MOC MOC categories Functional requirements PP PP P Processes Users TT TT T Tasks Requirements Application component Solution Standard modules Integration Custom development Existing application Manual procedure Copyright © 2005 World Batch 23 Forum Agenda · · · · What's wrong with MES and URS? ISA95 part 3 functional framework Methodology Conclusion Copyright © 2005 World Batch 24 Forum Conclusion · ISA95-3 offers a robust framework for MES requirements specification · This makes possible to keeping functional design in sync with URS allowing ­ Closer to expectations delivered solution ­ Consistent evolution ­ Core system build up Phase 1: Technical Modeling Phase 2: Business Processes Phase 3: Tasks Phase 4: Solution Selection Phase 5: Implementation Synchro However, it implies full User / Solution integrator agreement Copyright © 2005 World Batch 25 Forum