District 12 & Qatar Section Interoperability: ISA-95 part 2 / B2MML use cases Jean Vieille Control Chain Group Standards Certification Education & Training Publishing Conferences & Exhibits Past ISA D12 Vice President, France section President ISA-88/95/106 committee member ISA Automation Conference ­ Doha (Qatar) - 9 & 10 December 2012 Agenda · · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion 2 ISA-95 pradigm : Scope / goal This standard describes the interface content between manufacturing operations and control functions and other enterprise functions. .... The goals are to increase uniformity and consistency of interface terminology and reduce the risk, cost, and errors associated with implementing these interfaces. The standard can be used to reduce the effort associated with implementing new product offerings. The goal is to have enterprise systems and control systems that inter-operate and easily integrate. 3 ISA95 snapshot · B2M: Collaboration Business / Execution ­ Communication between execution systems (MES/MOM, DCS, MMS, LIMS, WES, SCADA,...) and business systems (ERP, SCM) ­ Master data management · MES/MOM : Functional definition · Data and Activity models ­ Description of resources, capability, products, work order requests and reports ­ Definition of operation management activities (MES) · Applications: ­ User requirements and functional specification of MES and B2M interfaces ­ Native B2M connectors - MES/ERP (B2MML) ­ Possible basis for developing MES applications and software... 4 What is ISA-95? · · · · US & International standard "Enterprise - Control System Integration" The ISA95 committee develops the ISA-95 standards The ISO/IEC JWG5 develops the international standard MSEA/WBF develops the XML implementation of the data models INTL Standard IEC/ISO 62264-1: 2003 IEC/ISO 62264-2: 2004 IEC/ISO 62264-3: 2007 IEC/ISO 62264-5: 2010 (APUB) Sub Title Part 1: Models and Terminology" Part 2: Data Structures and Attributes" Part 3: Activity Models of Manufacturing Operations Management Part 4: Objects and attributes for manufacturing operations management integration Part 5: Business to Manufacturing Transactions Business to Manufacturing Markup Language US standard ANSI/ISA-95.00.01: 2010 ANSI/ISA-95.00.02: 2010 ANSI/ISA-95.00.03: 2005 ANSI/ISA 95.00.04 2012 ASNI/ISA-95.00.05: 2007 + B2MML V06 5 Business-Operation systems Interface according to ISA95 part 2 Level 4 BusinessBusiness Planning & Logistics Systems (ERP, LIMS, WMS, MMS, SCM...) Level 3 Manufacturing Operations & Control Plant Production Scheduling, Operational Management, etc Manufacturing Systems Levels MES, ERP, LIMS, WES, MMS, SCE 2,1,0 DCS, PLCs, SCADA... Batch Continuous Discrete Control Control Control 6 Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... ISA-95 part 2 Models and terminology for manufacturing information Business planning & logistics information Plant production scheduling, operational management, etc (Operation) definition information (What must be defined to make The job) (Operation) capability information (What resources are available) (Operation) schedule information (What actual job will be executed) (Operation) performance information (What actual job was achieved) Manufacturing operations management information Production operations, maintenance operations, quality operations, etc Operations = Production, Maintenance, Quality, Inventory 7 Agenda · · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion 8 Context and challenge · Central ERP system + hundreds of factories worldwide · 3 selected control/MES vendors · Difficult decision taken between ­ Let vendors taking care of integration ­ Adopt a company wide interoperability language : vendor neutral / company responsible ISA-95 interface · Designed in Europe, developed in India, implemented and used everywhere 9 Interface scope : 20 messages (phase 1) ERP->MES Production transaction · Production Orders · PO status change MES-> ERP · PO reports : material produced, consummed, down times · PO status change · TO reports and cancellation · "Spontaneous" transfer · Raw material reception · Material status change · Inventory query Logistics transactions · Transfer Orders ­ in and inter plants Inventory transactions · Material status change · Inventory response 10 Work methodology · Messages identification and content provided by ERP functional consultants ­ Factories IT, MES vendors / integrators were never invited! ­ Opportunistic design, no high level guidance · Mapping of message through workshops involving ­ ERP consultants, ISA-95 expert · Extension and adaptation of ISA-95, B2MML ­ Company specific B2MML and ISA-95 extensions to overcome their limitations at this time (2004) ­ a major input for the next releases ­ ISA-95: Handling of inventory (and other) operations types ­ B2MML: Custom extensions 11 Specification structure · Very simple: ­ we don't care of systems but ERP ­ Everyone speaks SAP in the design team... ­ All other parties will just need to know ISA-95 (MES integrators) +ISA-95 models (ex : Operations Schedule) +Message (ex : Process Production orders) +Message rows ­ ISA-95 concept (ex : SegmentRequirement.ID) ­ SAP field (ex : Y_MES_H PPPI_CONTROL_RECIPE ) 12 not c udo P i r sr ed o r r ed o not c udo P r i r su a s t t r ed o not c udo P r i r sr e m r ap t a not c udo P i r es nops e R ProductionPerformance l ar e a M i t de mm s no C u SAP WM ProductionSchedule SAP PP-PI Example not c udo P i r s u a s r ed o t t r Any/Unknown MES / control systems l ar e a M i t dec udo P r Central ERP api ERP connector Distributued MES api 13 Enterprise bus ISA-95 messages MES connectors Outcome · Outcome ­ Design of ERP/MES through ISA-95 like enterprise language ­ only needs to be considered from ERP ­ can ignore MES ­ No need for ERP / MES meetings ­ Interface deployed worldwide ­ « Perfect delivery » ­ the initial spec/schemas are still in use - no update after 8 years ­ Subsequent extension for Quality · ISA-95 support : 40 days / 1 year ­ Detailed message definition, Functional specification writing ­ Many meetings... 14 Agenda · · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion 15 Context and challenge · Central ERP system + 3 factories in Europe · ESB Messaging framework available but deemed too expensive / complex => abandoned · Objective : ­ Enterprise controlled interfaces ­ Integration implemented by MES vendor using native systems interfaces 16 Interface scope : 14 messages ERP->MES Production transaction Inventory transactions Master data transactions · Production Orders · PO change · Sync material lots · Sync material definitions · Sync Equipment definitions MES-> ERP · PO reports : material produced, consumed, 17 Work methodology · Messages identification and content provided by company's business consultants · Build a taxonomy of the enterprise language · Provide a mapping ­ based on business terms ­ Providing translation in ERP and MES terminology · Only 3 meetings to gather requirements and wrap up the whole detailed mapping specification 18 Specification structure · More elaborated ­ The goal is to be understood by Business, ERP and MES people ­ Still simple: only 2 systems involved · Dictionary ­ Business terms with definitions +ISA-95 models (ex : Operations Schedule) +Messages + message rows ­ ­ ­ ­ ISA-95 concept (ex : SegmentRequirement.ID) Business data SAP data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) MES data (ex : Process Production orders) 19 Outcome · Outcome ­ A handy spec detailing all messages in 3 languages : ERP, MES and Business ­ understandable by all stakeholders ­ Only a specification ­ No messaging involved, ­ Direct peer to peer connexion between MES and ERP under vendor's responsibility · ISA-95 support: 15 days / 1 month ­ Detailed message definition 20 Agenda · · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion 21 Context and challenge · A complex interface project involving 7 different systems ­ The most complex among these 3 use cases · Strictly limited budget for external support ­ 2 days workshop planned for knowledge transfer ­ Design to realized internally 22 Interface scope : 20 messages ERP/MDM/LIMS/SCADA ->MES Production transaction Logistics transactions Quality transactions Inventory transactions Master data transactions ·Quality report · Material reception · Material quality · Sync material definitions · PO reports · Temperature reports MES-> ERP/LIMS/SCADA · deviation reports and ack · Production orders · Material movements Quality order · Weight control order 23 Work methodology Only 2 days budget : · 1st day : ­ Teach ISA-95+B2MML: High speed knowledge transfer ­ Team's brain overload ­ Manager's desperation : "Find another way by tomorrow" · 2nd day ­ All 20 messages identified and drafted ­ Definition of an XML enforced company language +ISA-95 spirit ­ Using an ISA-95 (really simple) meta-model · 3rd day (over-budget) ­ Review of the internal team work 24 Specification structure · Most sophisticated ­ Multiple systems involved * Definition of a company specific language, from the actual interoperability needs ­ No ISA-95 involved, but its rational +Transaction class (ex: material master) +ISA-95-like* models (ex : Material) +Transaction Messages + message rows ­ ­ ­ ­ ISA-95 concept (ex : SegmentRequirement.ID) Business data Origin system data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) Destination system (ex : Create Material) 25 Outcome · Outcome ­ Full autonomy achieved in 3 days ­ Smart design ­ Low cost · ISA-95 support : 3 days / 1week ­ Get the team thinking the ISA-95 way 26 Agenda · · · · · ISA95 snapshot Case 1 : Large company (>100 plants) Case 2 : medium company (3 plants) Case 3 : small company (single facility) Conclusion 27 Different way of leveraging the ISA-95 standard · Can be used for ­ Requirement specification (ISA-95) ­ Actual messages generation (BMML) · Can represent ­ The canonical enterprise language ­ A meta language for a company specific language · Is independent of the middleware technology ­ Peer-to-peer proprietary synchronous connexions ­ XML based asychronous messaging middleware ­ Other : text file transfer... · Investment varies in large extend ­ Almost independent of the scope and complexity 28 J. Vieille's Professional biography 37 years of experience in Information support to industrial systems · Control and management of industrial operations ­ Modular/Flexible Automation ISA-88 ­ Operations Management (MES/MOM) ISA-95 ­ IT Systems Interoperability B2MML · · Industrial IT governance and Organization ­ Support to Business Operations and transformation Software solutions ­ Assessment and selection ­ Functional architecture design roadmap, technology acquisitions · Information physics and systems theory ISA ­ Past D12 Vice President and France section President ­ ISA-88 and ISA-95 member 29 Thank You j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net Download this presentation (latest update) www.syntropicfactory.com/node/3799 30