.
District 12 & Qatar Section
ISA-95/B2MML Tutorial: Integration practice from use cases to xml messages
Jean Vieille
Standards Certification Education & Training Publishing Conferences & Exhibits
j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net
ISA Automation Conference Doha (Qatar) - 9 & 10 December 2012
Introduction
· This tutorial will first present successively:
A practical example of a fictitious industrial company to grasp basics of modeling patterns and interoperability realm of ISA-95 as well as B2MML messages content A methodology for specifying information flows The models from the recently updated ISA-95 part 2 and 4. The standard information services defined in ISA-95 part 5 The structure of the XML messages based on B2MML
2
Introduction
· Objective :
A quick overview of interoperability related ISA-95 parts be prepared to address integration between different manufacturing applications (ERP, control systems, MES, FCS, LIMS, CMMS...) in a consistent, efficient and documented manner.
· Participants
Industrial IT managers Project managers for integration Functional analysts involved in cross systems (i.e.ERP, MES, SCADA) business processes
3
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
4
Objectives
· This section exemplifies ISA-95 usage for
describing manufacturing facilities and operations Exchanging related information
· The different aspects of a fancy company and product serve as a basis for illustrating
Product industrialization Involved facilities Production planning Production reporting
· It makes use of simplified ISA95 UML models and B2MML textual representation
5
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
6
Products and Production organisation
· Understanding of product structure
Manufacturing stages Their relationships
· Outline the manufacturing strategy
In-house manufacturing, mono/multi process cells- Sites Synchronized contract manufacturing Purchasing
· Introduce Production definition, product segment
7
Product
· SuperToner The world's first wireless Internet enabled laser printer cartridges · Products are available for a selection of printers HP, Epson, Brother and Canon · Manufactured in 3 plants located in USA · The process includes the following stages:
Plastic molding Electronic board assembly for wireless connexion Printing ink manufacturing Assembly, filling and test Customizable packaging
8
Bill Of Material - Top Level Items
Printer Cartridge Ink Refill
Wireless Ethernet Sensor & Module
Customized Returnable Shipping Box
9
General product manufacturing structure
Cartridge top level product segments Plastic enclosure manufacturing Electronic board manufacturing Ink manufacturing Other parts
Manufactured Purchased
Assembly
10
Manufactured items
Enclosure Product Segments Plastic making Body Molding Cover Molding Finishing Pre-assembling
Ink Product Segments Reaction Sieving Refining Conditionning
Electronic Board Product Segments Engraving drilling Mounting Testing
11
Assembly
Assembly Product Segments Assembling Filling Print Test
Wireless test
Packaging
12
Product segment structure
Cartridge S1 S2 S3 S4 Enclosure Ink Electronic board Assembly
S1 Enclosure S1.1 Plastic making S1.2 Body molding S1.3 Cover molding S1.4 Finishing Preassembling
S2 Ink S2.1 Reaction S2.2 Sieving S2.3 Refining S2.4 Conditionning
S4 Assembly S4.1 S4.2 S4.3 S4.4 S4.5 Assembling Filling Print test Wireless test Packing
S3 Electronic board S3.1 S3.2 S3.3 S3.4 Engraving Drilling Mounting Testing
13
Product Families and variants
Families (one dimension) F1 Separable drum F2 Embedded drum Variants (multidimensional) V1 1 Canon Packing 2 HP Packing 3 Epson Packing V2 1 TN6600 OEM model 2 HX2200 OEM model
14
Simple manufacturing model
Super Toner
Plastic molding production line
Suppliers
Electronic board assembly Production line Ink manufacturing Process cell Assembly & Test Production Line
Customers
15
Cooperative manufacturing model
SuperToner Cartridge Manufacturer Suppliers Plastic molding & Assembly Plant Customers
Suppliers
Company B Electronic subcontractor Company C Ink subcontractor
Suppliers
16
Product segment allocation
SuperToner
S1: Make Enclosure S1.1 Plastic making S1.2 Body molding S1.3 Cover molding S1.4 Finishing Pre-assembling
Company C
S2: Make Ink S2.1 Reaction S2.2 Sieving S2.3 Refining S2.4 Conditionning
S4: Make Assembly S4.1 Assembling S4.2 Filling S4.3 Print test S4.4 Wireless test S4.5 Packing
Company B
S3: Make Electronic board S3.1 Engraving S3.2 Drilling S3.3 Mounting S3.4 Testing
17
Operations definition model
Operations Definition
May be made up of Has 1..n associated
Segment dependency 0..n Parameter
0..n
Operations Segment
0..n Equipment Specification
Must correspond to element in
0..n Personnel Specification
Must correspond to element in
0..n Material Specification
Must correspond to element in
Equipment Model
Personnel Model
Material Model
18
B2MML: Product Information 1st level product segments
<OperationsDefinitionInformation> <ID> F2 </ID> <Description> Embedded drum toner cartridges <HierarchyScope> <OperationsType>Production <PublishedDate> 2012-12-08 <OperationsDefinition> <ID> TN6600 <Version> V0 <Description> For Brother HL series <WorkDefinition> TN6600 <OperationsSegment> <ID> S1 <Description> Make Enclosure < OperationsSegment > <ID> S2 <Description> Make Ink
19
B2MML : 2nd level product segments
< OperationsSegment > <ID> S1.2 <Description> Body molding <Duration> 1 H <ProcessSegmentID> multi-mold workcell <ProcessSegmentID> Body+cover molding <SegmentDependency> Before S1.4 <Parameter> <ID> MoldReference <Value> M6600 <PersonnelSpecification> <PersonnelClassID> Molder <Description> <Quantity> 1 <EquipmentSpecification> <MaterialSpecification> <MaterialClass> Polyethylen <MaterialDefinitionID> P22 <Description> Rigid Polymer <MaterialUse> Consumed <Quantity> 234 G
20
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
21
Resources
· Identify the resources organisation:
Personnel Equipments Material & Energy Process Segments
22
Available resources: Equipment
SuperToner Equipment Manufacturer
Molding Line1
Molding Machine 1 Molding Machine 2 Molding Machine 3
Company B Electronic sub-contractor
Company C Ink sub-contractor
Solid Ink Pcell Liquid Ink Pcell
Blending Unit
Molding Line2
Molding Machine 4 Molding Machine 5 Engraving Unit Drilling Machine Mounting WkCell Testing WkCell
Reactor Unit Sieving & refining Unit
Conditionning Line
WkCell 1 WkCell 2
Assembly Line
WkCell 1 WkCell 2 WkCell 3
23
Available resources (at SuperToner plant)
Material Material Def. P22 P56 ECPH WLS25 Kit345 Class Polyethylen Polyethylen Ink Electronic board Accessories Lot PY2702 PY2906 E456 W1257 L35123 Qté 125 kg 54 kg 253 kg 49 56 Classe Molder Molder Molder Assembler Assembler Assembler Printing Tester Electronic Tester Lev. 1 1 2
Equipment ID Equipt E1 Machine1 E2 Machine2 E3 Machine3 E4 Machine4 E5 Machine5 E6 WkCell1 E7 WkCell2 E8 WkCell3
Classe Single molding Single molding Single molding Double molding Double molding Assembly station Assembly station Assembly station
Personnel ID Name P1 Albert P2 Bob P3 Chris P4 David P5 Eric P6 Francis P7 Greg P8 John
24
Personnel model
0..n 0..n Defined by
Personnel Class
Has properties Of
Person
Has values for
0..n Must map To
0..n
Personnel Class Property
Person Property
25
B2MML : Personnel
<PersonnelInformation> <Description> Personnel of SuperToner <PublishedDate> 2012-12-08 <PersonnelClass> <ID>Molder <Description> Molder <PersonnelClassProperty> <ID> MolderQualif <Description> Molder Qualification test <Value> 1 or 2 <QualificationTestSpecificationID> TestLevel <PersonID> <Person> <ID> P1 <PersonName> Albert <PersonnelClassID> Molder <PersonProperty> <ID> MolderQualif <Value> 1 <TestResult> Pass
26
Process Segment Concept
Personnel resources managed for production
People
Equipment resources managed for production
Equipment
Material resources managed for production
Materials
Collections of resources, used together for production, at the granularity needed for business level scheduling and costing
Segments
27
Available Resources : Process Segments
Id Sa1
Process Segment Body molding Cover molding Body + cover molding finishing + pre assembly
Personnel Class 1 molder Duration=1 H 1 molder Duration= 1H 1 molder Level=2 Duration= 1H 1 assembler Duration= 30'
Equipment Class
Material Class
Parameters MoldReference =M* MoldReference =M* MoldReference =M*
Single mold mach. Polyethyle n Duration= 1H Q=? Single mold mach. Q=? Duration= 1H Double mold mach. Duration= 1H Assembly worlkstation Duration= 30' Q=?
Sa2
Sa3
Sa4
ECPH Q=1 WLS25 Q=1
28
Process Segment model
0..n May be Made up of 0..n 0..n
Process Segment
Segment dependency
0..n
0..n
0..n
0..n
Parameter
Equipment Specification
Personnel Specification
Material Specification
corresponds to element in
corresponds to element in
corresponds to element in
Equipment Model
Personnel Model
Material Model
29
B2MML : Process Segments
<ProcessSegmentInformation> <ID> <Description> Available processes definition <HierarchyScope> <EquipmentID> SuperToner / Site <PublishedDate> 2012-12-08 <ProcessSegment> <ID> Sa1 <Description> Body molding <Duration> 1 H <PersonnelSegmentSpecification> <PersonnelClassID> Molder <EquipmentSegmentSpecification> <EquipmentClassID> Single mold. Mach. <MaterialSegmentSpecification> <MaterialClassID> Polyethylen <Parameter> <ID> MoldReference <Value> M* <ProcessSegment> <ProcessSegment>
30
Production Capability
· Resources are now identified · We have to provide information about allocation and availability
Within a given timeframe At a particular location For a type of capability: committed, available, unattaignable
· Caution :
The process segment capability overlaps the resource capability and those of other process segments
Risk of double use of the same resource
31
Production Capacity (cont'd)
Current Production Capacity
Unattainable Capacity Production Capacity
Capacity
Available Capacity
Committed Capacity
Current Capacity
Time
32
Operations Capability Model
Operations Capability
0..n Process segment Capability
0..n Equipment Capability
Must correspond to element in
0..n Personnel Capability
Must correspond to element in
0..n Material Capability
Must correspond to element in
Equipment Model
Personnel Model
Material Model
33
B2MML: Operations Capability - Header
< OperationsCapability> <ID> <Description> Plant capability <HierarchyScope> SuperToner / Site <PublishedDate> 2012-12-08 <CapabilityType> Committed <Reason> On request <EquipmentElementLevel> Site <StartTime> 2012-12-08 <EndTime> 2002-12-24 <PersonnelCapability>
<PersonID>
<EquipmentCapability>
<EquipmentID>
<MaterialCapability>
<MaterialDefinitionID>
<ProcessSegment>
<ID>
34
B2MML: Production capability - Personnel
<PersonnelCapability> <PersonnelClassID> Molder <CapabilityType> (default) <Reason> (default) < HierarchyScope > (default) <EquipmentElementLevel> (default) <StartTime> 2012-12-08 <EndTime> 2012-12-18 <Quantity> 5 <PersonnelCapabilityProperty>
<ID> MolderQualif <Value> 1 <Quantity> 2
2+1 ??? 5
<PersonnelCapabilityProperty>
<ID> MolderQualif <Value> 2 <Quantity> 1
35
B2MML: Process segments capability
<ProcessSegmentCapability> <ID> <Description> Body molding <ProcessSegmentID> SA1 <CapabilityType> <Reason> < HierarchyScope > <EquipmentElementLevel> <StartTime> 2012-12-08 <EndTime> 2012-12-18 <PersonnelCapability> <PersonnelClassID> Molder <Quantity> 1 <PersonnelCapabilityProperty> <ID> MolderQualif <Value> 1 <Quantity> 1 <EquipmentCapability> ... <MaterialCapability> ... <ProcessSegmentCapability>
36
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
37
Operations schedule
· The operations schedule relies on Operations and resources definitions
Operations schedule Operations Request Operations Request
Operations Request
Operations Request
Segment Segment Requirement Requirement
Segment Requirement
Segment Requirement
Resources
38
Operations schedule Corporate level
Operations schedule CARTRIDGES 2012-13-08
10 cartridges 50 cartridges TN6600 HX2200
...
...
Segment Segment Requirement Requirement Enclosures Ink
Segment Requirement Electronics
Segment Requirement Assembly
Resources = Plants, production lines
39
Operations schedule Plant level
Operations schedule SuperToner PLANT
10 enclosures HX2200
50 enclosures TN6600
...
...
Segment Requirement Sa1 Body Molding
Segment Requirement Sa2 Cover Molding
Segment Requirement Sa3 Finishing Pre-assembly.
Resources: Personnel, Equipment, Material
40
Operations schedule
Operations Schedule
Operations Definition
Corresponds to
Operations Request 1..n
Process or Operations Segment
Corresponds to
Segment Requirement
0..n Requested Segment Response
0..n
0..n
0..n
0..n
Segment Equipment Personnel Material Parameter Requirement Requirement Requirement
41
B2MML : Operations schedule
<OperationsSchedule> <ID> P020726 <Description> Updated schedule / urgent order <HierarchyScope> SuperToner / Site <PublishedDate> 2012-12-08 <StartTime> 2012-12-08 <EndTime> 2012-12-08 <OperationsRequest> <ID > OF212 <SegmentRequirement> <ID> Sa1 <Description> Body molding <Duration> 1 H <PersonnelSegmentSpecification> <PersonnelClassID> Molder <EquipmentSegmentSpecification> <EquipmentClassID> Single mold. Mach. <MaterialSegmentSpecification> <MaterialClassID> Polyethylen <MaterialDefinition> P22 <SegmentParameter> <ID> MoldReference <Value> M6600
42
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
43
Operations performance Corporate level
Operations performance (production) CARTRIDGES 2012-12-08
2 cartridges HX2200
4 cartridges TN6600
...
...
Segment actual Enclosure
Segment actual Ink
Segment actual Electronics
Segment actual Assembly
Resources
44
Operations performance Plant level
Operations performance (production) SuperToner PLANT
8 enclosures HX2200
7 enclosures TN6600
...
...
Segment actual Sa1 Body molding
Segment actual Sa2 Cover molding Resources
Segment actual Sa3 Finishing Pre-Assembly
45
Operations performance
Operations Performance
Operations Response
0..n
0..n Reports on
Operations Request
Segment Response
Corresponds to
Process Segment
0..n
0..n
0..n
0..n
Segment Data
Equipment Actual
Personnel Actual
Material
Actual
46
B2MML : Production performance
<OperationsPerformance> <ID> R020726 <Description> Daily production report <HierarchyScope> SuperToner / Site <PublishedDate> 2012-12-08 <OperationsScheduleID> P020726 <StartTime> 2012-12-08 T00:00:00Z <EndTime> 2012-12-08 T24:60:60Z <OperationsResponse> <ID> <OperationsRequestID> OF212 <SegmentResponse> <PersonnelActual> <PersonnelClassID> Molder <PersonID> Alfred <Description> <Quantity> 30min <EquipmentActual> <MaterialActual> <SegmentResponse>
47
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
48
Peer-to-peer vs Information service bus
Connect Connect Connect Connect Connect Connect
Appli A
Appli G
Appli A
Appli G
Appli B
Appli H
Appli B
. . MES / . B2M standardized messages
Connect
.
Appli H
Appli C
Appli I
Appli C
Connect
Appli I
Appli D
Appli J
Appli D
Connect Connect
Appli J
Appli E
Appli K
Appli E
Appli K
.
49
Exemple
50
Case 1 : ERP and MES not ISA-95 aware
Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML message Transform to MES message Send MES Message Receive MES Message
ERP Mess.
B2MML Mess.
ERP B2MML connector MES B2MML Connector
MES Mess.
ERP
MES
51
Case 2 : ERP is ISA-95 aware
Send B2MMLmessage Receive B2MML message Transform to MES message Send MES Message Receive MES Message
B2MML Mess.
MES Mess.
MES B2MML Connector
ERP
MES
52
Case 3 : ERP and MES not ISA-95 aware
Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML Message
ERP Mess.
B2MML Mess.
ERP B2MML connector
ERP
MES
53
Case 4 : ERP and MES not ISA-95 aware
Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML message Transform to MES message Send MES Message Receive MES Message
ERP Mess.
B2MML Mess.
ERP B2MML connector MES B2MML Connector
MES Mess.
ERP
MES
54
Case 4 : ERP and MES speak B2MML
Send B2MML message
Receive B2MML message
Warning! Custom Extensions Supported Transactions
B2MML Mess.
ERP
MES
55
Case 4 : B2MML mapping
Receive B2MML message Extension mapping Send B2MMLMessage Receive B2MML message
Send B2MML message
B2MML Mess.
B2MML Mess.
B2MML Router/mapper
ERP
MES
56
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
57
Enterprise bus ISA-95 messages
MES connectors
Methodology overview
Requirements
1 Business Glossary ISA-95 models 3 Business process 2 IT Applications
Design
4 Transactions & message identification 5 Message definitions (xsd)
Operations
Message Instances (xml)
58
1. Business Glossary
· Many « languages »
Each software solution has its own: « Batch » in ERP is « Lot » in MES, is SKU in warehouse system People may use a terminology based on
A well established company wide glossary the current software solution An ancien sotware solution An ancien plant owner ...
· ISA-95 brings an addiitonal one!
Can be an advantage: neutral language beyond possible political and personnal conflicts Can be problematic is the company has established its own terminology
59
1. Business Glossary: an opprotunity
· Designing interface is the right time to establish a common understanding on company's meta-data · ISA-95 is a semi-canonical standard
Imposes a given terminology for a limited set of terms
Standard structures and attributes: Production Request, Material Definition... All other data have are custom extensions through properties or extension attributes
· The « Glossary » shall be built / maintained
Defining an appropriate definition Matching the different terms with ISA-95 standard and extensions can be part of a semantic meta data registration process in the concept of a company-wide MDM effort
60
1. Business glossary example
Business Term Description Range - Codes BatchManagedIndicator Allow the theoretical use of Yes/No the component in quantity ContainerWeight Define the theoretical weight value of a container HasPotency Titrisation Yes/No IsWeighed WeighingMode The material has to be Yes/No weighed List of authorized weighing 1. Net weighing methods 2. Double weighing 3. Forced input 4. Keyboard gross weighing 5. Lure gross weighing 6. Manual input 7. Authorization to mix different components 8. Counting weighing (capsule) 9. Pallet weighing 10.Laser weighing
61
2. IT applications
ID MES ERP OPZ Solution FLEXNET SAP Formula+ Description Inventory management Production management Formula optimizer
62
3. Business Processes
· Describe Business process workflows
Identify use cases involving inter-system communications Describe workflows, identifies communication instances
· BP example: Process Order Optimization
Use case:
optimize the formula before executing a production order, taking into account the characteristics of raw material to be used
Simplified :
We only consider the part where interoperability is involved
63
3. Business process
ERP
Create / Release Production Requests Manage Material
MES
OPZ
Execute Production Requests
Optimize Production Requests
64
4. Transactions & message identification
· For each communication link, identify transactions · For each transaction,
Decide for a transaction model (Push, Pull, Publish) identify the involved messages
· For each message
Give et business relevant name and unique ID IT application origin and destination ISA-05 applicable model ISA-95 part 5 verb (action to perform) ISA-95 par 2/4 noun (the conveyed information)
65
4. Transactions & message identification
ERP
Create / Release Production Requests Manage Material
MES
s et r epo pl ar e a M i r i t
OPZ
T6 T3
T2
qe R not c udo P denna P i r l e R not c udo P de uc ex E i r t R not c udo P dez m p O i r i it
T1
T5
Optimized Production Requests Material Properties
Execute Production Requests
Optimize Production Requests
T4
66
T1: Planned Production Requests ERP-> MES
ERP
PUSH
MES
M1.1: Send Planned Production Requests
PROCESS Operations Schedule
Note: no confirmation / acknowledgement at the application level
67
T2: Executed Production Requests MES -> ERP
MES
PUSH
M2.1 Send Production Responses
PROCESS Operations Performance
ERP
Note: no confirmation / acknowledgement at the application level
68
T3: Material properties ERP to MES
MES
PULL
M3.1 Query Material Properties
GET Material Lot
ERP
M3.2 Send Material Properties
SHOW Material Lot
69
T4: Material properties MES -> Optimizer
MES
PUBLISH
M4.1 Send Material Properties
SYNC Material Lot
OPZ
70
T5: Optimized Production Requests MES <-> Optimizer
MES
PUSH
M5.1 Send Planned Production Requests
PROCESS Operations Schedule
OPZ
M5.2 Send Optimized Production Requests
ACKNOWLEDGE Operations Schedule
71
T6: Optimized Production Requests MES -> ERP
MES
PUSH
ERP
M6.1 Send Optimized Production Requests
PROCESS Operations Schedule
72
Message summary
# Transaction Mode T1 Planned PUSH Production Requests T2 Executed PUSH Production Requests T3 Material PULL Properties (MES) T4 Material Properties (OPZ) T5 Optimized Production Requests PUBLISH M.4.1 PUSH M.5.1 Send Material Properties Send Planned Production Requests Send Optimized Production Requests Send Optimized Production Requests Mateiral Operations Schedule SYNC Material Lot MES Operations Schedule OPZ Mess. Message ISA-95 ID name Modèle Send Planned Production Operations M1.1 Requests Schedule Send Production Operations M2.1 Responses Performance Query Material M3.1 Properties Material Send Material M.3.2 Properties Material Verb Noun Operations Schedule Origin Dest.
PROCESS
ERP
MES
PROCESS GET SHOW
Operations Performance MES Material lot Material Lot MES ERP
ERP ERP MES
PROCESS
MES
OPZ
M.5.2 T6 Optimized Production Requests PUSH
Operations Schedule
Operations Acknowledge Schedule
OPZ
MES
M.6.1
Operations Schedule
PROCESS
Operations Schedule
MES
ERP
73
5. Message definition
· Messages data mapping
Business data correspond to ISA-95 data
Existing attributes in the model tree structure Custom attributes extending the appropriate objetcts
Feuille Microsoft Office Excel 97-2003
AND applications data As a consequence, a message row relates ISA-95 concept (ex : SegmentRequirement.ID) Business data (ex : Process Order) SAP data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) MES data (ex : PO_ID)
· Each message mapping is an independent sub-project
Interface projects can be split at will : per business process, per system..
Note : The presented example is not included in the conference material (customer information)
74
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
75
5. Categories of information / part 2
Enterprise Information
Plant Production Scheduling, Operational Management, etc
Definition Capability Information Information
(What it takes to make a job) (What resources are available)
Schedule Performance
(What to make and use) (What was made and used)
Manufacturing Control Information
Area Supervision, Production, Scheduling, Reliability, Assurance, etc
76
5. Categories of information / part 4
Definition Capability Information Information
(What it takes to make a job) (What resources are available)
Schedule Performance
(What to make and use) (What was made and used)
Manufacturing Control Information
77
Extended interoperability domains
Represented in the Operations Schedule model Represented in the Operations Performance model
Production schedule
Maintenance request
Quality Test request
Inventory request
Production Maintenance performance response
Quality Test response
Inventory response
Manufacturing operations management
Production operations management Maintenance operations management Quality operations management Inventory operations management
Product definition
Maintenance definition
Quality Test definition
Inventory definition
Production capability
Maintenance capability
Quality Test capability
Inventory capability
Represented in the Operations Definition model
Represented in the Operations Capability model 78
ISA-95 part 2/4 models
Category Resource ISA-95.02 Personnel Role based equipment, Physical asset, physical model, Material Resource relationship network Poential Knowledge Process segment Operations definition Operations / Kinetic knowledge Operations schedule Operations performance Operations capability Work Alert Work definition Work schedule Work performance Work capability ISA-95.04
79
Personnel (part 2)
· Includes
persons and personnel classes (categories) properties as Skills and capabilities of individuals (persons) and groups (classes) Qualification Tests associated to properties Results associated to property, individual and test
80
Personnel (part 2)
Personnel Class
Has properties of > 0..n 0..n Is tested by a > 0..n 0..n < Defined by 0..n Is tested by a > 0..n Has values for >
Person
Qualification Test Specification
0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n < Records the execution of 0..n
Qualification Test Result
0..n
Personnel Class Property
Person Property
0..n < may contain nested
0..n < may contain nested
81
Equipment (part 2)
· Split in 2 view points
Role based equipment (that participates in a segment activity as a functional entity) Physical Asset (that identifies a given specific equipment regardless its current function / status)
· Includes
equipment and equipment classes (type of equipment) properties as characteristics / capabilities of equipment / equipment classes Capability Tests associated to properties Results associated to property, equipment and test
82
Role based equipment (part 2)
< May be made up of 0..n
Equipment Class
Has properties of >
0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n
Equipment
Has values for >
Equipment Capability Test Specification
0..n Is tested by an > Defines a procedure for obtaining an > 0..n Maps to 0..n 0..n < Records the execution of
Equipment Capability Test Result
Equipment Class Property
0..n
0..n
Equipment Property
0..n < may contain nested
0..n < may contain nested
83
Physical asset (part 2)
> May be made up of 0..n > is an instance of
Physical Asset
Has values for >
1..1 0..n Is tested by an > 0..n
0..n 0..n Is tested by an > 0..n
Physical Asset Class
Has properties of >
Physical Asset Capability Test Result
< records the testing of Defines a procedure for obtaining an < 0..n
Physical Asset Capability Test Specification
0..n 0..n Is tested by an < Maps to 0..n
0..n
0..n
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
84
Role based equipment / physical asset relationship (part 2)
< May be made up of 0..n > May be made up of 0..n > Implemented by
Equipment Class
Has properties of >
0..n 0..n < Defined by
Equipment
0..1
0..1
< records use and removal of asset to implement equipment
Physical Asset
> is an instance of 0..n
1..1
Physical Asset Class
Has properties of >
Equipment Asset Mapping
0..n 0..n 0..n 0..n Maps to
Equipment Class Property
Maps to
Equipment Property
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
0..n < may contain nested
0..n < may contain nested
85
Material model (part 2)
· Includes
material definitions (article id) and material classes (categories of material) Material Lots and Sublots with location information Properties as characteristics of material definitions, classes, lots, sublots Material Tests associated to properties Results associated to property, material lot/sublot and test
86
Material model (part 2)
Is assembled from Is assembled from Is assembled from Is assembled from
0..n
0..n Defines a grouping 0..n
0..n 0..n 1..1 Defined by
0..n Made up of
0..n
0..n
Material Class
Has properties of
0..n
Material Definition
Has properties of
Material Lot
0..n
Material Sublot
0..n
Is tested by a >
Is tested by a > 0..n 0..n 0..n
Is tested by a > 0..n
Has values for
Has values for
May be made up of sublots
Material Test Specification
Defines a procedure for obtaining a 0..n Records the execution of
Is tested by a > 0..n
0..n Is tested by a > 0..n
QA Test Result
0..n
0..n
Material Class Property
0..n < may contain nested
May map to
Material Definition Property
0..n < may contain nested
0..n Maps to
0..n
Material Lot Property
0..n
0..n < may contain nested
87
Process segment (part 2)
· A process segment: the process view for the business system to control material, labor, resource usage, cost, and quality in order to control the production can be more or less detailed and self contained providing a "telescopic" view of manufacturing capabilities of a given facility Also called: Process stages, process operations, Unit operations, Assembly steps and assembly actions The model Defines Capability, Parameters & Resources used by the Segment (Personnel, Equipment & Materials) The Segment pattern appears in all subsequent models
·
· ·
88
Process segment (part 2)
· Business view of production Pharmaceutical Manufacturing
(3 Segments) Make Active Ingredient Make Pills Package Doses
Raw Materials
Finished Products
Inventory tracked for Active Ingredient Know throughput, resources and time to make Active Ingredient
Inventory tracked for Pills
Inventory tracked for Pill Packs
Know throughput, resources and time to make Pills
Know throughput, resources and time to make Pill Packs
89
Process segment (part 2)
0..n has an execution dependency on
Process Segment
is a collection of
0..n
0..n May be made up of
Process Segment Dependency
0..n
0..n
0..n
0..n
0..n
Process Segment Parameter
0..n May be made up of
Personnel Segment Specification
Has properties of 0..n
Equipment Segment Specification
Has properties of 0..n
Physical Asset Segment Specification
Has properties of 0..n
Material Segment Specification
0..n Is assembled from
Has properties of 0..n
Personnel Segment Specification Property
0..n Corresponds to element in 1..1
Equipment Segment Specification Property
0..n Corresponds to element in 1..1
Physical Asset Segment Specification Property
0..n Corresponds to element in 1..1
Material Segment Specification Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
90
Resource relationship network (part 4)
Resource Relationship Netw ork
class Resource Relationship Netw ork
1..* Resource Netw ork Connection «deri ve» Resource Netw ork Connection Type
1 To Resource Reference
1 From Resource Reference
0..* Resource Netw ork Connection Property
0..* Resource Netw ork Connection Type Property
«deri ve»
0..* To Resource Reference Property
0..* From Resource Reference Property
+Corresponds to el ements in
+Corresponds to el ements i n
Resource Models
notes Any of the Personnel , Equi ment, Materi al , Physi cal Asset, Work Process Segment, or Process Segment model s
91
Capability
· Uniquely define the production capability for a specific element of the equipment model Given for specific resources as well as segments Provide a description of - or other information about the production capability Provide current state of the capability (available, committed, or unattainable) Define a location for the capability Define the physical level of the capability (Enterprise, Site, Area, Process Cell...) Define a Start Time and End Time that defines the lifecycle time for the capability Document the publish date for when the capability was published or generated
· · · · · ·
92
Operations capability (part 2)
Operations Capability
1 Is a collection of
0..n
0..n
0..n
0..n
0..n
Process Segment Capability
Personnel Capability
Has properties of 1 0..n
Equipment Capability
Has properties of 1 0..n
Physical Asset Capability
Has properties of 1 0..n
Material Capability
0..n Is assembled from
Has properties of 1 0..n
Personnel Capability Property
0..n Corresponds to element in 1..1
Equipment Capability Property
0..n Corresponds to element in 1..1
Physical Asset Capability Property
0..n Corresponds to element in 1..1
Material Capability Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
93
Process segment capability (part 2)
Process Segment Capability
Corresponds to
Process Segment
Is a collection of
0..n
0..n
0..n
0..n
Personnel Capability
Has properties of 0..n
Equipment Capability
Has properties of 0..n
Physical Asset Capability
Has properties of 0..n
Material Capability
Has properties of 0..n
0..n Is assembled from
Personnel Capability Property
0..n Corresponds to element in 1..1
Equipment Capability Property
0..n Corresponds to element in 1..1
Physical Asset Capability Property
0..n Corresponds to element in 1..1
Material Capability Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
94
Work capability (part 4)
class Work Capability Model Work Capability
0..* Word Master Capability
0..* Personnel Capability
0..* Equipment Capability
0..* Physical Asset Capability
0..* Material Capability
+Is assembled from 0..* 0..* Personnel Capability Property 0..* Equipment Capability Property 0..* Physical Asset Capability Property 0..* Material Capability Property
+Corresponds to element in
0..* 1
+Corresponds to element in
0..* 1
+Corresponds 0..* to element in 1 Physical Asset Model
+Corresponds to element in
0..* 1
Personnel Model
Equipment Model
Material Model
95
Work Master capability (part 4)
class Work Master Capability Model Work Master Capability Work Master +Corresponds to 0..* 1
0..* Personnel Capability
0..* Equipment Capability
0..* Physical Asset Capability
0..* Material Capability
+Is assembled from 0..* 0..* Personnel Capability Property 0..* Equipment Capability Property 0..* Physical Asset Capability Property 0..* Material Capability Property
+Corresponds to element i n
0..* 1
+Corresponds to element in
0..* 1
+Corresponds to element in
0..* 1
+Corresponds to element in
0..* 1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
96
Definition
· A definition specifies the resources required to perform a specified operation such as making a product, maintaining an equipment, teaching an operator, executing a quality analysis or moving materials.
Defines a sequence of "Operations segments"
· It does not describes how to perform this work in detail, though this information can be handled as
general, site or master recipe (IEC 61512-1 and ANSI/ISAS88.01-1995 definition), standard operating procedure (SOP), standard operating conditions (SOC), And attached to the Operations definition and its segments
97
Operations definition (part 2)
Has a reference to < Has a reference to >
Bill of Resources (External)
Has associated > May be made up of 0..n has an execution dependency on 0..n 0..n
Operations Definition
Has associated 0..n 1..n 1..1
Work Definition (External)
Bill of Material (External)
may have a reference to >
Has associated > 0..n
May have a reference to > Corresponds to 0..n 1..n
Operations Material Bill
0..n
Operations Segment
Process Segment
Operations Segment Dependency
0..n 0..n
Is a collection of
1..1 0..n
Operations Material Bill Item
0..n Is assembled from
0..n
0..n
0..n
1..n
Parameter Specification
0..n May be made up of
Personnel Specification
Equipment Specification
Physical Asset Specification
Material Specification
0..n Is assembled from
0..n
0..n
0..n
0..n
Personnel Specification Property
0..n Corresponds to element in
Equipment Specification Property
0..n Corresponds to element in
Physical Asset Specification Property
0..n Corresponds to element in
Material Specification Property
0..n Corresponds to element in
1..1
1..1
1..1
1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
98
Work definition (part 4)
class Work Definition Model Operations Definition +May have reference to Work Definition
Abstract Type Work Master 1 +is created from 0..* Work Directiv e
0..*
0..*
+May be made up of 0..*
0..* Parameter Specification
0..* Personnel Specification
0..* Equipment Specification
0..* Physical Asset Specification
0..* Material Specification +Is assembled from 0..*
0..* Workflow Specification
0..* Personnel Specification Property
0..* Equipment Specification Property
0..* Physical Asset Property
0..* Material Specification Property
+Corresponds to element in
0..*
+Corresponds to element in
0..*
+Corresponds to element in
0..*
+Corresponds to element in
0..*
1 Personnel Model
1 Equipment Model
1 Physical Asset Model
1 Material Model
99
Schedule
· What to make and what to use · Operations schedule information
Is a collection of Operations Requests
· Operations request
information required to fulfill the scheduled operation.
a collection of Segment Requirements
May reference the associated operations instructions
· A segment Requirement
Shall correspond to an existing operations or process segment Defines specific Equipment, Personnel, Material requirements and Operations parameters There may only be one production segment,
But at least one!
100
Operations schedule (part 2)
Operations Definition
Operations Schedule
Is made up of 1..n May correspond to an <
Operations Request
Is made up of May correspond to an < 1..n 0..n
Process Segment
Corresponds to an <
Segment Requirement
0..n May contain 0..n
Requested Segment Response
May contain
0..n
0..n
0..n
0..n
Segment Parameter
0..n May be made up of Corresponds to a
Personnel Requirement
Equipment Requirement
Physical Asset Requirement
Material Requirement
0..n Is assem bled from
1..n
1..n
1..n
1..n
Personnel Requirement Property
Corresponds to element in the
Equipment Requirement Property
Physical Asset Requirement Property
Material Requirement Property
Corresponds to element in the
Corresponds to element in the
Corresponds to element in the
Parameter Specification or Process Segment Parameter
Personnel Model
Equipment Model
Physical Asset Model
Material Model
101
Work Schedule (part 4)
Work Schedule
Job List Work Request
+Made be made up of 0..*
1..* Work Master +Corresponds to Job Order
1..*
+May be made up of 0..*
+May be made up of 0..*
0..* Job Order Parameter
0..* Personnel Requirement
0..* Equipment Requirement
0..* Physical Asset Requirement
0..* Material Requirement
+Is assembled from 0..* 0..* Personnel Requirement Property 0..* Equipment Requirement Property 0..* Physical Asset Requirement Property 0..* Material Requirement Property
+Corresponds to element in 1 Personnel Model
+Corresponds to element in 1 Equipment Model
+Corresponds to element in 1 Physical Asset Model
+Corresponds to element in 1 Material Model
102
Performance
What was made and what was used - example · A Operations Performance
Is a collection of Operations Responses
· A Operations Response
Is a collection of Segment Response Corresponds to a specific Production Request
· A segment Response
Correspond to a specific segment requirement Reports What resources were actually used, consumed, produced and other production data
103
Operations performance (part 2)
Operations Definition
Operations Performance
Is made up of 1..n May correspond to a > 0..n 0..1
May correspond to an <
Operations Response
Operations Request
Is made up of May correspond to an < 1..n
Process Segment
Corresponds to a <
Segment Response
0..n
May contain
May contain
0..n
0..n
0..n
0..n
0..n
Segment Data
0..n May be made up of
Personnel Actual
Equipment Actual
Physical Asset Actual
Material Actual
0..n Is assembled from
1..n
1..n
1..n
1..n
Personnel Actual Property
Corresponds to element in
Equipment Actual Property
Physical Asset Actual Property
Corresponds to element in
Material Actual Property
Corresponds to element in
Corresponds to element in
Personnel Model
Equipment Model
Physical Asset Model
Material Model
104
Work performance (part 4)
Work Performance
+May be m ade up of 0..* Work Response
+May be made up of 0..* +Is made up of 1..* Job Response Work Directiv e +Corrsponds to 0..1 +May be made up of 0..*
0..* +May be made up Job Response Data of 0..*
0..* Personnel Actual
0..* Equipment Actual
0..* Physical Asset Actual
0..* Material Actual
+Is assem bl ed from 0..* 0..* Personnel Actual Property 0..* Equipment Actual Property 0..* Physical Asset Actual Property 0..* Material Actual Property
+Corresponds to el ement in
0..*
+Correspondes to el ement in
0..*
+Correspondes to element i n
0..*
+Correspondes to element i n
0..*
1 Personnel Model
1 Equipment Model
1 Physical Asset Model
1 Material Model
105
Segments, Segments, Segments...
· Process segment: manufacturing capability
Defines the manufacturing process available per segment Gather the required resources to execute the defined operations segments
· Operations/Work Segment: manufacturing requirements
Defines the specifications per operations segment Details the required resources for this operations segment
· Segment Requirement: run time requirements
Defines the specifics for an operations request
· Segment Response
Reports the actual happening
106
Segments, Segments, Segments...
Operaitons / Work capability
Operations / Work definition
Operations segment ·Parameter ·Resource specification
Operations / Work schedule
Segment requirement ·Parameter ·Resource requirement
Operations / Work performance
Segment response ·Parameter ·Resource actual
Process segment ·Parameter ·Resource specification
107
s n o i t a r e p O
s n o i t a r e p O i t a m r o f n I l u s r d n e k m o t a h W
Summary / part 2 e lb v is t a h W
m r o f n I y t l i b p a C e c r u o s R t l i y b a C p h W c u o s e r t a ilb v e r a t O o i a p s n r e t n m g e S y t l i b p a C o d e b n c t a h W u o s r e h it w c s e c o r P s t n m g e S s io c n u f t a h W ilb v e r a o s t n io t a r e p m f s n o i t a r e p O o t n i f e D t w o H an in t a r e p o m o f r e p s n o i t a r e p O l u d e h c S e b o is t a h W m s u & e d a s n t a r e io p O l u d e h c S
s n o i t a r e p O c n a m o f r e P s w t a h W s u & e d a m s n io t a r e p O c n a m o f r e P
May correspond to a
s n io t a r e p O y ilt b p a C
s n io t a r e p O o t in f e D
s n t a r e io p O t s u q e R
s n io t a r e p O n o p s e R
May correspond to a
Must correspond to a
Must correspond to a
May correspond May correspond to a to a
s n io t a r e p O t n m g e S y ilt b p a C
s e c o r P t n m g e S
s n io t a r e p O t n m g e S
t n m g e S t n m ir u q e R
t n m g e S n o p s e R
May correspond to a
May correspond to a
May correspond to a
c r u o s e R y ilt b p a C
c r u o s e R y ilt b p a C
c r u o s e R S n o t a if c e p
c r u o s e R S n o t a if c e p
c r u o s e R m ir u q e t n R
c r u o s e R l a u t c A
May correspond to a
May correspond to a
May correspond to a
May correspond to a
c r u o s e R y ilt b p a C P r y t e p o
c r u o s e R y ilt b p a C y t e p o r P
c r u o s e R S n o t a if c e p y t e p o r P
c r u o s e R n o t a if c e p S y t e p o r P
c r u o s e R t n m ir u q e R y t e p o r P
c r u o s e R l a u t c A y t e p o r P
108
m r o f n I y t l i b p a C Summary / part 4 e ilb v a s t h W
k r o W
c r u o s e R y t l i b p a C c u o s e r t a h W ilb v e r a
k r o W e t s a M r a C i b p t l y o d e b n c t a h W c u o s r e h it w y ilt b p a C k r o W
m f r e p t w o H
r k o W e t s a M r k r o w
e b o is t a h W d m o f r e P im t y b c u o s r & e
b o J t s i L
k r o W l u d e h c S e b o is t a h W d m o f r e P c n a m o f r e P
k r o W s w t a h W d m o f r e p v t c e r i D m f r e p t w o H b jo if c e p s a
k r o W
l u d e h c S
k r o W
d n p s e r o C
a o t
c n a m o f r e P
k r o W
t is L b o J
t s u q e R k r o W d n p s e r o C a o t
n p s e R k r o W
k r o W r e t s a M b p a C y ilt
d n p s e r o C a o t
k r o W r e t s a M
d n p s e r o C
a o t
e d r O b o J
d n p s e r o C
n p s e R b o J a o t
d n p s e r o C a o t
k r o W v t c e ir D
o r u s c e R a C y ilt b p
d n p s e r o C
a o t
c r u o s e R t n m g e S y ilt b p a C
d n p s e r o C a o t
o e R c r u s n o t a if c e p S
d n p s e r o C
a o t
c r u o s e R t n m ir u q e R
d n p s e r o C
a o t
c r u o s e R l a u t c A
d n p s e r o C a o t
c r u o s e R n o t a if c e p S
o e R r u s c y ilt b a p C e p r P y t o
d n p s e r o C
a o t
c r u o s e R t n m g e S y ilt b p a C y t e p o r P
d n p s e r o C a o t c r u o s e R
R o e c r u s n o t a if c e p S P r o y e p t
d n p s e r o C
a o t
c r u o s e R t n m ir u q e R y t e p o r P
d n p s e r o C
a o t
c r u o s e R l a u t c A y t e p o r P
d n p s e r o C a o t
c r u o s e R n o t a if c e p S y t e p o r P
P M A a c y h t m ip u q E l, n o s r e
109
AGENDA
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
110
ISA95 part 5
· The Open Application Group OAG publishes an extensive XML schema specification for exhanging information to/from/between business systems (ERP)
www.openapplications.org It sometimes overlaps with ISA95
· Currently (04/2008) version 9.2, includes some ISA95 models · OAGIS defines messages based on a VERB-NOUN combination to properly handle complete transactions
Allowing Push/Pull/Publish-Subscribe transactional modes
· The ISA95 part 5 standard extend part 1/2 to specify applicable transactions/messages
It only use a subset of the OAGIS VBERBS
111
Messages et transactions
Message : · a structured Owner of information information unit conveyed in a oneLocal way transfer of data processing from one sending application to one or more receiving applications Transaction : SHOW · a sequence of related messages that are exchanged among applications
GET Equipment
Application Identification Area Data Area VERB = GET Noun = Equipment ID= "ABC"
User of information
GET
SHOW Equipment
Application Identification Area Data Area VERB = SHOW Noun = Equipment ID= "ABC" Description = "Simple equipment" Equipment Property ID = "Throughput" Value = 200 PPM Description = "Throughput as parts per minute" ...
112
Message Structure
· Content of a message: Application identification area
typically includes the electronic address of the sender, an indication of the confirmation requirement, and the date and time the message was created ...
Message Application Identification Area Data Area VERB NOUN
Data Area VERB
defines the action to be performed, or the response to a request
Data Area NOUN
represents one or more objects, as defined in the Part 1 and Part 2 object models
·
The above information defines a unique and unambiguous meaning of messages
113
Verb list
Verb ACKNOWLEDGE CANCEL CHANGE CONFIRM
Description Acknowledgement of a PROCESS request. Request to a receiver to remove information. Request to a receiver to change information. Confirmation response to a request.
Model PUSH PUSH PUSH PUSH, PULL PUBLISH PULL PUSH PUSH PULL PUBLISH PUBLISH PUBLISH
GET PROCESS RESPOND SHOW SYNC ADD SYNC CHANGE SYNC DELETE
Request to a receiver for information on one or more objects. Request to a receiver to process new information. Response to a CHANGE message request. Response to a GET message. Request from the owner of the object to add information Request from the owner of the object to change information Request from the owner of the object to delete information
Noun list
Personnel Class Person Qualification Test Specification Equipment Class Equipment Equipment Capability Test Specification Physical Asset Class Physical Asset Physical Asset Capability Test Specification Material Class Material Definition Material Lot Material Sublot Material Test Specification Resource Relationship Network Connection Type Resource Relationship Network Connection Process Segment Operations Capability Work Capability Operations Definition Work Directive Work Master Workflow specification Operations Schedule Work Schedule Job list Operations Performance Work Performance Work Alert Transaction Service Profile
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
116
Overview
· The ISA95 object models may be used as the basis for formalized information exchange protocols
Such as SQL tables, XML internet files, or IDL object definitions
· B2MML is originally an XML implementation of ISA95
Along with BatchML for ISA88
· B2MML = ISA88+ISA95 data structures implementation
BatchML (ISA88 part 2) and new ISA88 models (Part 3 and 4) are now merged into B2MML
· B2MML is developed by the WBF
WBF is an ISA sponsored/supported organization B2MML is for "Business To Manufacturing Markup Language" Has become the de facto implementation standard for business to manufacturing information exchange
· B2MML benefit of a reactive development environment
About 1 version / year
117
Example: Personnel schema
Information About Personnel Classes Information About Tests Information About Persons
Personnel Class
Has properties of >
0..n 0..n Is tested by a > 0..n
0..n < Defined by 0..n Is tested by a > 0..n
Person
Has values for >
Qualification Test Specification
0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n < Records the execution of 0..n
Qualification Test Result
0..n
Personnel Class Property
Person Property
118
Example: Personnel schema - Header
119
Extension mechanism
120
Example: Personnel schema root element
121
Download the latests
· This presentation (and many others)
http://www.syntropicfactory.com/node/3798
· B2MML
http://wbforg.affiniscape.com/displaycommon.cfm?an=1&subarticlenbr= https://services.mesa.org/ResourceLibrary/ViewCategory/8c65bee5-db
· ISA95 committee
http://www.isa.org/isa95
122
Thank You j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net
123
ISA-95/B2MML Tutorial: Integration practice from use cases to xml messages
Jean Vieille
Standards Certification Education & Training Publishing Conferences & Exhibits
j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net
ISA Automation Conference Doha (Qatar) - 9 & 10 December 2012
Introduction
· This tutorial will first present successively:
A practical example of a fictitious industrial company to grasp basics of modeling patterns and interoperability realm of ISA-95 as well as B2MML messages content A methodology for specifying information flows The models from the recently updated ISA-95 part 2 and 4. The standard information services defined in ISA-95 part 5 The structure of the XML messages based on B2MML
2
Introduction
· Objective :
A quick overview of interoperability related ISA-95 parts be prepared to address integration between different manufacturing applications (ERP, control systems, MES, FCS, LIMS, CMMS...) in a consistent, efficient and documented manner.
· Participants
Industrial IT managers Project managers for integration Functional analysts involved in cross systems (i.e.ERP, MES, SCADA) business processes
3
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
4
Objectives
· This section exemplifies ISA-95 usage for
describing manufacturing facilities and operations Exchanging related information
· The different aspects of a fancy company and product serve as a basis for illustrating
Product industrialization Involved facilities Production planning Production reporting
· It makes use of simplified ISA95 UML models and B2MML textual representation
5
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
6
Products and Production organisation
· Understanding of product structure
Manufacturing stages Their relationships
· Outline the manufacturing strategy
In-house manufacturing, mono/multi process cells- Sites Synchronized contract manufacturing Purchasing
· Introduce Production definition, product segment
7
Product
· SuperToner The world's first wireless Internet enabled laser printer cartridges · Products are available for a selection of printers HP, Epson, Brother and Canon · Manufactured in 3 plants located in USA · The process includes the following stages:
Plastic molding Electronic board assembly for wireless connexion Printing ink manufacturing Assembly, filling and test Customizable packaging
8
Bill Of Material - Top Level Items
Printer Cartridge Ink Refill
Wireless Ethernet Sensor & Module
Customized Returnable Shipping Box
9
General product manufacturing structure
Cartridge top level product segments Plastic enclosure manufacturing Electronic board manufacturing Ink manufacturing Other parts
Manufactured Purchased
Assembly
10
Manufactured items
Enclosure Product Segments Plastic making Body Molding Cover Molding Finishing Pre-assembling
Ink Product Segments Reaction Sieving Refining Conditionning
Electronic Board Product Segments Engraving drilling Mounting Testing
11
Assembly
Assembly Product Segments Assembling Filling Print Test
Wireless test
Packaging
12
Product segment structure
Cartridge S1 S2 S3 S4 Enclosure Ink Electronic board Assembly
S1 Enclosure S1.1 Plastic making S1.2 Body molding S1.3 Cover molding S1.4 Finishing Preassembling
S2 Ink S2.1 Reaction S2.2 Sieving S2.3 Refining S2.4 Conditionning
S4 Assembly S4.1 S4.2 S4.3 S4.4 S4.5 Assembling Filling Print test Wireless test Packing
S3 Electronic board S3.1 S3.2 S3.3 S3.4 Engraving Drilling Mounting Testing
13
Product Families and variants
Families (one dimension) F1 Separable drum F2 Embedded drum Variants (multidimensional) V1 1 Canon Packing 2 HP Packing 3 Epson Packing V2 1 TN6600 OEM model 2 HX2200 OEM model
14
Simple manufacturing model
Super Toner
Plastic molding production line
Suppliers
Electronic board assembly Production line Ink manufacturing Process cell Assembly & Test Production Line
Customers
15
Cooperative manufacturing model
SuperToner Cartridge Manufacturer Suppliers Plastic molding & Assembly Plant Customers
Suppliers
Company B Electronic subcontractor Company C Ink subcontractor
Suppliers
16
Product segment allocation
SuperToner
S1: Make Enclosure S1.1 Plastic making S1.2 Body molding S1.3 Cover molding S1.4 Finishing Pre-assembling
Company C
S2: Make Ink S2.1 Reaction S2.2 Sieving S2.3 Refining S2.4 Conditionning
S4: Make Assembly S4.1 Assembling S4.2 Filling S4.3 Print test S4.4 Wireless test S4.5 Packing
Company B
S3: Make Electronic board S3.1 Engraving S3.2 Drilling S3.3 Mounting S3.4 Testing
17
Operations definition model
Operations Definition
May be made up of Has 1..n associated
Segment dependency 0..n Parameter
0..n
Operations Segment
0..n Equipment Specification
Must correspond to element in
0..n Personnel Specification
Must correspond to element in
0..n Material Specification
Must correspond to element in
Equipment Model
Personnel Model
Material Model
18
B2MML: Product Information 1st level product segments
<OperationsDefinitionInformation> <ID> F2 </ID> <Description> Embedded drum toner cartridges <HierarchyScope> <OperationsType>Production <PublishedDate> 2012-12-08 <OperationsDefinition> <ID> TN6600 <Version> V0 <Description> For Brother HL series <WorkDefinition> TN6600 <OperationsSegment> <ID> S1 <Description> Make Enclosure < OperationsSegment > <ID> S2 <Description> Make Ink
19
B2MML : 2nd level product segments
< OperationsSegment > <ID> S1.2 <Description> Body molding <Duration> 1 H <ProcessSegmentID> multi-mold workcell <ProcessSegmentID> Body+cover molding <SegmentDependency> Before S1.4 <Parameter> <ID> MoldReference <Value> M6600 <PersonnelSpecification> <PersonnelClassID> Molder <Description> <Quantity> 1 <EquipmentSpecification> <MaterialSpecification> <MaterialClass> Polyethylen <MaterialDefinitionID> P22 <Description> Rigid Polymer <MaterialUse> Consumed <Quantity> 234 G
20
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
21
Resources
· Identify the resources organisation:
Personnel Equipments Material & Energy Process Segments
22
Available resources: Equipment
SuperToner Equipment Manufacturer
Molding Line1
Molding Machine 1 Molding Machine 2 Molding Machine 3
Company B Electronic sub-contractor
Company C Ink sub-contractor
Solid Ink Pcell Liquid Ink Pcell
Blending Unit
Molding Line2
Molding Machine 4 Molding Machine 5 Engraving Unit Drilling Machine Mounting WkCell Testing WkCell
Reactor Unit Sieving & refining Unit
Conditionning Line
WkCell 1 WkCell 2
Assembly Line
WkCell 1 WkCell 2 WkCell 3
23
Available resources (at SuperToner plant)
Material Material Def. P22 P56 ECPH WLS25 Kit345 Class Polyethylen Polyethylen Ink Electronic board Accessories Lot PY2702 PY2906 E456 W1257 L35123 Qté 125 kg 54 kg 253 kg 49 56 Classe Molder Molder Molder Assembler Assembler Assembler Printing Tester Electronic Tester Lev. 1 1 2
Equipment ID Equipt E1 Machine1 E2 Machine2 E3 Machine3 E4 Machine4 E5 Machine5 E6 WkCell1 E7 WkCell2 E8 WkCell3
Classe Single molding Single molding Single molding Double molding Double molding Assembly station Assembly station Assembly station
Personnel ID Name P1 Albert P2 Bob P3 Chris P4 David P5 Eric P6 Francis P7 Greg P8 John
24
Personnel model
0..n 0..n Defined by
Personnel Class
Has properties Of
Person
Has values for
0..n Must map To
0..n
Personnel Class Property
Person Property
25
B2MML : Personnel
<PersonnelInformation> <Description> Personnel of SuperToner <PublishedDate> 2012-12-08 <PersonnelClass> <ID>Molder <Description> Molder <PersonnelClassProperty> <ID> MolderQualif <Description> Molder Qualification test <Value> 1 or 2 <QualificationTestSpecificationID> TestLevel <PersonID> <Person> <ID> P1 <PersonName> Albert <PersonnelClassID> Molder <PersonProperty> <ID> MolderQualif <Value> 1 <TestResult> Pass
26
Process Segment Concept
Personnel resources managed for production
People
Equipment resources managed for production
Equipment
Material resources managed for production
Materials
Collections of resources, used together for production, at the granularity needed for business level scheduling and costing
Segments
27
Available Resources : Process Segments
Id Sa1
Process Segment Body molding Cover molding Body + cover molding finishing + pre assembly
Personnel Class 1 molder Duration=1 H 1 molder Duration= 1H 1 molder Level=2 Duration= 1H 1 assembler Duration= 30'
Equipment Class
Material Class
Parameters MoldReference =M* MoldReference =M* MoldReference =M*
Single mold mach. Polyethyle n Duration= 1H Q=? Single mold mach. Q=? Duration= 1H Double mold mach. Duration= 1H Assembly worlkstation Duration= 30' Q=?
Sa2
Sa3
Sa4
ECPH Q=1 WLS25 Q=1
28
Process Segment model
0..n May be Made up of 0..n 0..n
Process Segment
Segment dependency
0..n
0..n
0..n
0..n
Parameter
Equipment Specification
Personnel Specification
Material Specification
corresponds to element in
corresponds to element in
corresponds to element in
Equipment Model
Personnel Model
Material Model
29
B2MML : Process Segments
<ProcessSegmentInformation> <ID> <Description> Available processes definition <HierarchyScope> <EquipmentID> SuperToner / Site <PublishedDate> 2012-12-08 <ProcessSegment> <ID> Sa1 <Description> Body molding <Duration> 1 H <PersonnelSegmentSpecification> <PersonnelClassID> Molder <EquipmentSegmentSpecification> <EquipmentClassID> Single mold. Mach. <MaterialSegmentSpecification> <MaterialClassID> Polyethylen <Parameter> <ID> MoldReference <Value> M* <ProcessSegment> <ProcessSegment>
30
Production Capability
· Resources are now identified · We have to provide information about allocation and availability
Within a given timeframe At a particular location For a type of capability: committed, available, unattaignable
· Caution :
The process segment capability overlaps the resource capability and those of other process segments
Risk of double use of the same resource
31
Production Capacity (cont'd)
Current Production Capacity
Unattainable Capacity Production Capacity
Capacity
Available Capacity
Committed Capacity
Current Capacity
Time
32
Operations Capability Model
Operations Capability
0..n Process segment Capability
0..n Equipment Capability
Must correspond to element in
0..n Personnel Capability
Must correspond to element in
0..n Material Capability
Must correspond to element in
Equipment Model
Personnel Model
Material Model
33
B2MML: Operations Capability - Header
< OperationsCapability> <ID> <Description> Plant capability <HierarchyScope> SuperToner / Site <PublishedDate> 2012-12-08 <CapabilityType> Committed <Reason> On request <EquipmentElementLevel> Site <StartTime> 2012-12-08 <EndTime> 2002-12-24 <PersonnelCapability>
<PersonID>
<EquipmentCapability>
<EquipmentID>
<MaterialCapability>
<MaterialDefinitionID>
<ProcessSegment>
<ID>
34
B2MML: Production capability - Personnel
<PersonnelCapability> <PersonnelClassID> Molder <CapabilityType> (default) <Reason> (default) < HierarchyScope > (default) <EquipmentElementLevel> (default) <StartTime> 2012-12-08 <EndTime> 2012-12-18 <Quantity> 5 <PersonnelCapabilityProperty>
<ID> MolderQualif <Value> 1 <Quantity> 2
2+1 ??? 5
<PersonnelCapabilityProperty>
<ID> MolderQualif <Value> 2 <Quantity> 1
35
B2MML: Process segments capability
<ProcessSegmentCapability> <ID> <Description> Body molding <ProcessSegmentID> SA1 <CapabilityType> <Reason> < HierarchyScope > <EquipmentElementLevel> <StartTime> 2012-12-08 <EndTime> 2012-12-18 <PersonnelCapability> <PersonnelClassID> Molder <Quantity> 1 <PersonnelCapabilityProperty> <ID> MolderQualif <Value> 1 <Quantity> 1 <EquipmentCapability> ... <MaterialCapability> ... <ProcessSegmentCapability>
36
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
37
Operations schedule
· The operations schedule relies on Operations and resources definitions
Operations schedule Operations Request Operations Request
Operations Request
Operations Request
Segment Segment Requirement Requirement
Segment Requirement
Segment Requirement
Resources
38
Operations schedule Corporate level
Operations schedule CARTRIDGES 2012-13-08
10 cartridges 50 cartridges TN6600 HX2200
...
...
Segment Segment Requirement Requirement Enclosures Ink
Segment Requirement Electronics
Segment Requirement Assembly
Resources = Plants, production lines
39
Operations schedule Plant level
Operations schedule SuperToner PLANT
10 enclosures HX2200
50 enclosures TN6600
...
...
Segment Requirement Sa1 Body Molding
Segment Requirement Sa2 Cover Molding
Segment Requirement Sa3 Finishing Pre-assembly.
Resources: Personnel, Equipment, Material
40
Operations schedule
Operations Schedule
Operations Definition
Corresponds to
Operations Request 1..n
Process or Operations Segment
Corresponds to
Segment Requirement
0..n Requested Segment Response
0..n
0..n
0..n
0..n
Segment Equipment Personnel Material Parameter Requirement Requirement Requirement
41
B2MML : Operations schedule
<OperationsSchedule> <ID> P020726 <Description> Updated schedule / urgent order <HierarchyScope> SuperToner / Site <PublishedDate> 2012-12-08 <StartTime> 2012-12-08 <EndTime> 2012-12-08 <OperationsRequest> <ID > OF212 <SegmentRequirement> <ID> Sa1 <Description> Body molding <Duration> 1 H <PersonnelSegmentSpecification> <PersonnelClassID> Molder <EquipmentSegmentSpecification> <EquipmentClassID> Single mold. Mach. <MaterialSegmentSpecification> <MaterialClassID> Polyethylen <MaterialDefinition> P22 <SegmentParameter> <ID> MoldReference <Value> M6600
42
Agenda
· Example
Product structure and Manufacturing strategy Resources & Capability Operations Schedule Operations Performance
· · · ·
Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
43
Operations performance Corporate level
Operations performance (production) CARTRIDGES 2012-12-08
2 cartridges HX2200
4 cartridges TN6600
...
...
Segment actual Enclosure
Segment actual Ink
Segment actual Electronics
Segment actual Assembly
Resources
44
Operations performance Plant level
Operations performance (production) SuperToner PLANT
8 enclosures HX2200
7 enclosures TN6600
...
...
Segment actual Sa1 Body molding
Segment actual Sa2 Cover molding Resources
Segment actual Sa3 Finishing Pre-Assembly
45
Operations performance
Operations Performance
Operations Response
0..n
0..n Reports on
Operations Request
Segment Response
Corresponds to
Process Segment
0..n
0..n
0..n
0..n
Segment Data
Equipment Actual
Personnel Actual
Material
Actual
46
B2MML : Production performance
<OperationsPerformance> <ID> R020726 <Description> Daily production report <HierarchyScope> SuperToner / Site <PublishedDate> 2012-12-08 <OperationsScheduleID> P020726 <StartTime> 2012-12-08 T00:00:00Z <EndTime> 2012-12-08 T24:60:60Z <OperationsResponse> <ID> <OperationsRequestID> OF212 <SegmentResponse> <PersonnelActual> <PersonnelClassID> Molder <PersonID> Alfred <Description> <Quantity> 30min <EquipmentActual> <MaterialActual> <SegmentResponse>
47
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
48
Peer-to-peer vs Information service bus
Connect Connect Connect Connect Connect Connect
Appli A
Appli G
Appli A
Appli G
Appli B
Appli H
Appli B
. . MES / . B2M standardized messages
Connect
.
Appli H
Appli C
Appli I
Appli C
Connect
Appli I
Appli D
Appli J
Appli D
Connect Connect
Appli J
Appli E
Appli K
Appli E
Appli K
.
49
Exemple
50
Case 1 : ERP and MES not ISA-95 aware
Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML message Transform to MES message Send MES Message Receive MES Message
ERP Mess.
B2MML Mess.
ERP B2MML connector MES B2MML Connector
MES Mess.
ERP
MES
51
Case 2 : ERP is ISA-95 aware
Send B2MMLmessage Receive B2MML message Transform to MES message Send MES Message Receive MES Message
B2MML Mess.
MES Mess.
MES B2MML Connector
ERP
MES
52
Case 3 : ERP and MES not ISA-95 aware
Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML Message
ERP Mess.
B2MML Mess.
ERP B2MML connector
ERP
MES
53
Case 4 : ERP and MES not ISA-95 aware
Send ERP message Receive ERP message Transform to B2MML message Send B2MML message Receive B2MML message Transform to MES message Send MES Message Receive MES Message
ERP Mess.
B2MML Mess.
ERP B2MML connector MES B2MML Connector
MES Mess.
ERP
MES
54
Case 4 : ERP and MES speak B2MML
Send B2MML message
Receive B2MML message
Warning! Custom Extensions Supported Transactions
B2MML Mess.
ERP
MES
55
Case 4 : B2MML mapping
Receive B2MML message Extension mapping Send B2MMLMessage Receive B2MML message
Send B2MML message
B2MML Mess.
B2MML Mess.
B2MML Router/mapper
ERP
MES
56
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
57
Enterprise bus ISA-95 messages
MES connectors
Methodology overview
Requirements
1 Business Glossary ISA-95 models 3 Business process 2 IT Applications
Design
4 Transactions & message identification 5 Message definitions (xsd)
Operations
Message Instances (xml)
58
1. Business Glossary
· Many « languages »
Each software solution has its own: « Batch » in ERP is « Lot » in MES, is SKU in warehouse system People may use a terminology based on
A well established company wide glossary the current software solution An ancien sotware solution An ancien plant owner ...
· ISA-95 brings an addiitonal one!
Can be an advantage: neutral language beyond possible political and personnal conflicts Can be problematic is the company has established its own terminology
59
1. Business Glossary: an opprotunity
· Designing interface is the right time to establish a common understanding on company's meta-data · ISA-95 is a semi-canonical standard
Imposes a given terminology for a limited set of terms
Standard structures and attributes: Production Request, Material Definition... All other data have are custom extensions through properties or extension attributes
· The « Glossary » shall be built / maintained
Defining an appropriate definition Matching the different terms with ISA-95 standard and extensions can be part of a semantic meta data registration process in the concept of a company-wide MDM effort
60
1. Business glossary example
Business Term Description Range - Codes BatchManagedIndicator Allow the theoretical use of Yes/No the component in quantity ContainerWeight Define the theoretical weight value of a container HasPotency Titrisation Yes/No IsWeighed WeighingMode The material has to be Yes/No weighed List of authorized weighing 1. Net weighing methods 2. Double weighing 3. Forced input 4. Keyboard gross weighing 5. Lure gross weighing 6. Manual input 7. Authorization to mix different components 8. Counting weighing (capsule) 9. Pallet weighing 10.Laser weighing
61
2. IT applications
ID MES ERP OPZ Solution FLEXNET SAP Formula+ Description Inventory management Production management Formula optimizer
62
3. Business Processes
· Describe Business process workflows
Identify use cases involving inter-system communications Describe workflows, identifies communication instances
· BP example: Process Order Optimization
Use case:
optimize the formula before executing a production order, taking into account the characteristics of raw material to be used
Simplified :
We only consider the part where interoperability is involved
63
3. Business process
ERP
Create / Release Production Requests Manage Material
MES
OPZ
Execute Production Requests
Optimize Production Requests
64
4. Transactions & message identification
· For each communication link, identify transactions · For each transaction,
Decide for a transaction model (Push, Pull, Publish) identify the involved messages
· For each message
Give et business relevant name and unique ID IT application origin and destination ISA-05 applicable model ISA-95 part 5 verb (action to perform) ISA-95 par 2/4 noun (the conveyed information)
65
4. Transactions & message identification
ERP
Create / Release Production Requests Manage Material
MES
s et r epo pl ar e a M i r i t
OPZ
T6 T3
T2
qe R not c udo P denna P i r l e R not c udo P de uc ex E i r t R not c udo P dez m p O i r i it
T1
T5
Optimized Production Requests Material Properties
Execute Production Requests
Optimize Production Requests
T4
66
T1: Planned Production Requests ERP-> MES
ERP
PUSH
MES
M1.1: Send Planned Production Requests
PROCESS Operations Schedule
Note: no confirmation / acknowledgement at the application level
67
T2: Executed Production Requests MES -> ERP
MES
PUSH
M2.1 Send Production Responses
PROCESS Operations Performance
ERP
Note: no confirmation / acknowledgement at the application level
68
T3: Material properties ERP to MES
MES
PULL
M3.1 Query Material Properties
GET Material Lot
ERP
M3.2 Send Material Properties
SHOW Material Lot
69
T4: Material properties MES -> Optimizer
MES
PUBLISH
M4.1 Send Material Properties
SYNC Material Lot
OPZ
70
T5: Optimized Production Requests MES <-> Optimizer
MES
PUSH
M5.1 Send Planned Production Requests
PROCESS Operations Schedule
OPZ
M5.2 Send Optimized Production Requests
ACKNOWLEDGE Operations Schedule
71
T6: Optimized Production Requests MES -> ERP
MES
PUSH
ERP
M6.1 Send Optimized Production Requests
PROCESS Operations Schedule
72
Message summary
# Transaction Mode T1 Planned PUSH Production Requests T2 Executed PUSH Production Requests T3 Material PULL Properties (MES) T4 Material Properties (OPZ) T5 Optimized Production Requests PUBLISH M.4.1 PUSH M.5.1 Send Material Properties Send Planned Production Requests Send Optimized Production Requests Send Optimized Production Requests Mateiral Operations Schedule SYNC Material Lot MES Operations Schedule OPZ Mess. Message ISA-95 ID name Modèle Send Planned Production Operations M1.1 Requests Schedule Send Production Operations M2.1 Responses Performance Query Material M3.1 Properties Material Send Material M.3.2 Properties Material Verb Noun Operations Schedule Origin Dest.
PROCESS
ERP
MES
PROCESS GET SHOW
Operations Performance MES Material lot Material Lot MES ERP
ERP ERP MES
PROCESS
MES
OPZ
M.5.2 T6 Optimized Production Requests PUSH
Operations Schedule
Operations Acknowledge Schedule
OPZ
MES
M.6.1
Operations Schedule
PROCESS
Operations Schedule
MES
ERP
73
5. Message definition
· Messages data mapping
Business data correspond to ISA-95 data
Existing attributes in the model tree structure Custom attributes extending the appropriate objetcts
Feuille Microsoft Office Excel 97-2003
AND applications data As a consequence, a message row relates ISA-95 concept (ex : SegmentRequirement.ID) Business data (ex : Process Order) SAP data (ex : Y_MES_H PPPI_CONTROL_RECIPE ) MES data (ex : PO_ID)
· Each message mapping is an independent sub-project
Interface projects can be split at will : per business process, per system..
Note : The presented example is not included in the conference material (customer information)
74
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
75
5. Categories of information / part 2
Enterprise Information
Plant Production Scheduling, Operational Management, etc
Definition Capability Information Information
(What it takes to make a job) (What resources are available)
Schedule Performance
(What to make and use) (What was made and used)
Manufacturing Control Information
Area Supervision, Production, Scheduling, Reliability, Assurance, etc
76
5. Categories of information / part 4
Definition Capability Information Information
(What it takes to make a job) (What resources are available)
Schedule Performance
(What to make and use) (What was made and used)
Manufacturing Control Information
77
Extended interoperability domains
Represented in the Operations Schedule model Represented in the Operations Performance model
Production schedule
Maintenance request
Quality Test request
Inventory request
Production Maintenance performance response
Quality Test response
Inventory response
Manufacturing operations management
Production operations management Maintenance operations management Quality operations management Inventory operations management
Product definition
Maintenance definition
Quality Test definition
Inventory definition
Production capability
Maintenance capability
Quality Test capability
Inventory capability
Represented in the Operations Definition model
Represented in the Operations Capability model 78
ISA-95 part 2/4 models
Category Resource ISA-95.02 Personnel Role based equipment, Physical asset, physical model, Material Resource relationship network Poential Knowledge Process segment Operations definition Operations / Kinetic knowledge Operations schedule Operations performance Operations capability Work Alert Work definition Work schedule Work performance Work capability ISA-95.04
79
Personnel (part 2)
· Includes
persons and personnel classes (categories) properties as Skills and capabilities of individuals (persons) and groups (classes) Qualification Tests associated to properties Results associated to property, individual and test
80
Personnel (part 2)
Personnel Class
Has properties of > 0..n 0..n Is tested by a > 0..n 0..n < Defined by 0..n Is tested by a > 0..n Has values for >
Person
Qualification Test Specification
0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n < Records the execution of 0..n
Qualification Test Result
0..n
Personnel Class Property
Person Property
0..n < may contain nested
0..n < may contain nested
81
Equipment (part 2)
· Split in 2 view points
Role based equipment (that participates in a segment activity as a functional entity) Physical Asset (that identifies a given specific equipment regardless its current function / status)
· Includes
equipment and equipment classes (type of equipment) properties as characteristics / capabilities of equipment / equipment classes Capability Tests associated to properties Results associated to property, equipment and test
82
Role based equipment (part 2)
< May be made up of 0..n
Equipment Class
Has properties of >
0..n 0..n 0..n Is tested by an > 0..n < Defined by 0..n Is tested by an > 0..n
Equipment
Has values for >
Equipment Capability Test Specification
0..n Is tested by an > Defines a procedure for obtaining an > 0..n Maps to 0..n 0..n < Records the execution of
Equipment Capability Test Result
Equipment Class Property
0..n
0..n
Equipment Property
0..n < may contain nested
0..n < may contain nested
83
Physical asset (part 2)
> May be made up of 0..n > is an instance of
Physical Asset
Has values for >
1..1 0..n Is tested by an > 0..n
0..n 0..n Is tested by an > 0..n
Physical Asset Class
Has properties of >
Physical Asset Capability Test Result
< records the testing of Defines a procedure for obtaining an < 0..n
Physical Asset Capability Test Specification
0..n 0..n Is tested by an < Maps to 0..n
0..n
0..n
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
84
Role based equipment / physical asset relationship (part 2)
< May be made up of 0..n > May be made up of 0..n > Implemented by
Equipment Class
Has properties of >
0..n 0..n < Defined by
Equipment
0..1
0..1
< records use and removal of asset to implement equipment
Physical Asset
> is an instance of 0..n
1..1
Physical Asset Class
Has properties of >
Equipment Asset Mapping
0..n 0..n 0..n 0..n Maps to
Equipment Class Property
Maps to
Equipment Property
Physical Asset Property
0..n < may contain nested
Physical Asset Class Property
0..n < may contain nested
0..n < may contain nested
0..n < may contain nested
85
Material model (part 2)
· Includes
material definitions (article id) and material classes (categories of material) Material Lots and Sublots with location information Properties as characteristics of material definitions, classes, lots, sublots Material Tests associated to properties Results associated to property, material lot/sublot and test
86
Material model (part 2)
Is assembled from Is assembled from Is assembled from Is assembled from
0..n
0..n Defines a grouping 0..n
0..n 0..n 1..1 Defined by
0..n Made up of
0..n
0..n
Material Class
Has properties of
0..n
Material Definition
Has properties of
Material Lot
0..n
Material Sublot
0..n
Is tested by a >
Is tested by a > 0..n 0..n 0..n
Is tested by a > 0..n
Has values for
Has values for
May be made up of sublots
Material Test Specification
Defines a procedure for obtaining a 0..n Records the execution of
Is tested by a > 0..n
0..n Is tested by a > 0..n
QA Test Result
0..n
0..n
Material Class Property
0..n < may contain nested
May map to
Material Definition Property
0..n < may contain nested
0..n Maps to
0..n
Material Lot Property
0..n
0..n < may contain nested
87
Process segment (part 2)
· A process segment: the process view for the business system to control material, labor, resource usage, cost, and quality in order to control the production can be more or less detailed and self contained providing a "telescopic" view of manufacturing capabilities of a given facility Also called: Process stages, process operations, Unit operations, Assembly steps and assembly actions The model Defines Capability, Parameters & Resources used by the Segment (Personnel, Equipment & Materials) The Segment pattern appears in all subsequent models
·
· ·
88
Process segment (part 2)
· Business view of production Pharmaceutical Manufacturing
(3 Segments) Make Active Ingredient Make Pills Package Doses
Raw Materials
Finished Products
Inventory tracked for Active Ingredient Know throughput, resources and time to make Active Ingredient
Inventory tracked for Pills
Inventory tracked for Pill Packs
Know throughput, resources and time to make Pills
Know throughput, resources and time to make Pill Packs
89
Process segment (part 2)
0..n has an execution dependency on
Process Segment
is a collection of
0..n
0..n May be made up of
Process Segment Dependency
0..n
0..n
0..n
0..n
0..n
Process Segment Parameter
0..n May be made up of
Personnel Segment Specification
Has properties of 0..n
Equipment Segment Specification
Has properties of 0..n
Physical Asset Segment Specification
Has properties of 0..n
Material Segment Specification
0..n Is assembled from
Has properties of 0..n
Personnel Segment Specification Property
0..n Corresponds to element in 1..1
Equipment Segment Specification Property
0..n Corresponds to element in 1..1
Physical Asset Segment Specification Property
0..n Corresponds to element in 1..1
Material Segment Specification Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
90
Resource relationship network (part 4)
Resource Relationship Netw ork
class Resource Relationship Netw ork
1..* Resource Netw ork Connection «deri ve» Resource Netw ork Connection Type
1 To Resource Reference
1 From Resource Reference
0..* Resource Netw ork Connection Property
0..* Resource Netw ork Connection Type Property
«deri ve»
0..* To Resource Reference Property
0..* From Resource Reference Property
+Corresponds to el ements in
+Corresponds to el ements i n
Resource Models
notes Any of the Personnel , Equi ment, Materi al , Physi cal Asset, Work Process Segment, or Process Segment model s
91
Capability
· Uniquely define the production capability for a specific element of the equipment model Given for specific resources as well as segments Provide a description of - or other information about the production capability Provide current state of the capability (available, committed, or unattainable) Define a location for the capability Define the physical level of the capability (Enterprise, Site, Area, Process Cell...) Define a Start Time and End Time that defines the lifecycle time for the capability Document the publish date for when the capability was published or generated
· · · · · ·
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Operations capability (part 2)
Operations Capability
1 Is a collection of
0..n
0..n
0..n
0..n
0..n
Process Segment Capability
Personnel Capability
Has properties of 1 0..n
Equipment Capability
Has properties of 1 0..n
Physical Asset Capability
Has properties of 1 0..n
Material Capability
0..n Is assembled from
Has properties of 1 0..n
Personnel Capability Property
0..n Corresponds to element in 1..1
Equipment Capability Property
0..n Corresponds to element in 1..1
Physical Asset Capability Property
0..n Corresponds to element in 1..1
Material Capability Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
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Process segment capability (part 2)
Process Segment Capability
Corresponds to
Process Segment
Is a collection of
0..n
0..n
0..n
0..n
Personnel Capability
Has properties of 0..n
Equipment Capability
Has properties of 0..n
Physical Asset Capability
Has properties of 0..n
Material Capability
Has properties of 0..n
0..n Is assembled from
Personnel Capability Property
0..n Corresponds to element in 1..1
Equipment Capability Property
0..n Corresponds to element in 1..1
Physical Asset Capability Property
0..n Corresponds to element in 1..1
Material Capability Property
0..n Corresponds to element in 1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
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Work capability (part 4)
class Work Capability Model Work Capability
0..* Word Master Capability
0..* Personnel Capability
0..* Equipment Capability
0..* Physical Asset Capability
0..* Material Capability
+Is assembled from 0..* 0..* Personnel Capability Property 0..* Equipment Capability Property 0..* Physical Asset Capability Property 0..* Material Capability Property
+Corresponds to element in
0..* 1
+Corresponds to element in
0..* 1
+Corresponds 0..* to element in 1 Physical Asset Model
+Corresponds to element in
0..* 1
Personnel Model
Equipment Model
Material Model
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Work Master capability (part 4)
class Work Master Capability Model Work Master Capability Work Master +Corresponds to 0..* 1
0..* Personnel Capability
0..* Equipment Capability
0..* Physical Asset Capability
0..* Material Capability
+Is assembled from 0..* 0..* Personnel Capability Property 0..* Equipment Capability Property 0..* Physical Asset Capability Property 0..* Material Capability Property
+Corresponds to element i n
0..* 1
+Corresponds to element in
0..* 1
+Corresponds to element in
0..* 1
+Corresponds to element in
0..* 1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
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Definition
· A definition specifies the resources required to perform a specified operation such as making a product, maintaining an equipment, teaching an operator, executing a quality analysis or moving materials.
Defines a sequence of "Operations segments"
· It does not describes how to perform this work in detail, though this information can be handled as
general, site or master recipe (IEC 61512-1 and ANSI/ISAS88.01-1995 definition), standard operating procedure (SOP), standard operating conditions (SOC), And attached to the Operations definition and its segments
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Operations definition (part 2)
Has a reference to < Has a reference to >
Bill of Resources (External)
Has associated > May be made up of 0..n has an execution dependency on 0..n 0..n
Operations Definition
Has associated 0..n 1..n 1..1
Work Definition (External)
Bill of Material (External)
may have a reference to >
Has associated > 0..n
May have a reference to > Corresponds to 0..n 1..n
Operations Material Bill
0..n
Operations Segment
Process Segment
Operations Segment Dependency
0..n 0..n
Is a collection of
1..1 0..n
Operations Material Bill Item
0..n Is assembled from
0..n
0..n
0..n
1..n
Parameter Specification
0..n May be made up of
Personnel Specification
Equipment Specification
Physical Asset Specification
Material Specification
0..n Is assembled from
0..n
0..n
0..n
0..n
Personnel Specification Property
0..n Corresponds to element in
Equipment Specification Property
0..n Corresponds to element in
Physical Asset Specification Property
0..n Corresponds to element in
Material Specification Property
0..n Corresponds to element in
1..1
1..1
1..1
1..1
Personnel Model
Equipment Model
Physical Asset Model
Material Model
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Work definition (part 4)
class Work Definition Model Operations Definition +May have reference to Work Definition
Abstract Type Work Master 1 +is created from 0..* Work Directiv e
0..*
0..*
+May be made up of 0..*
0..* Parameter Specification
0..* Personnel Specification
0..* Equipment Specification
0..* Physical Asset Specification
0..* Material Specification +Is assembled from 0..*
0..* Workflow Specification
0..* Personnel Specification Property
0..* Equipment Specification Property
0..* Physical Asset Property
0..* Material Specification Property
+Corresponds to element in
0..*
+Corresponds to element in
0..*
+Corresponds to element in
0..*
+Corresponds to element in
0..*
1 Personnel Model
1 Equipment Model
1 Physical Asset Model
1 Material Model
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Schedule
· What to make and what to use · Operations schedule information
Is a collection of Operations Requests
· Operations request
information required to fulfill the scheduled operation.
a collection of Segment Requirements
May reference the associated operations instructions
· A segment Requirement
Shall correspond to an existing operations or process segment Defines specific Equipment, Personnel, Material requirements and Operations parameters There may only be one production segment,
But at least one!
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Operations schedule (part 2)
Operations Definition
Operations Schedule
Is made up of 1..n May correspond to an <
Operations Request
Is made up of May correspond to an < 1..n 0..n
Process Segment
Corresponds to an <
Segment Requirement
0..n May contain 0..n
Requested Segment Response
May contain
0..n
0..n
0..n
0..n
Segment Parameter
0..n May be made up of Corresponds to a
Personnel Requirement
Equipment Requirement
Physical Asset Requirement
Material Requirement
0..n Is assem bled from
1..n
1..n
1..n
1..n
Personnel Requirement Property
Corresponds to element in the
Equipment Requirement Property
Physical Asset Requirement Property
Material Requirement Property
Corresponds to element in the
Corresponds to element in the
Corresponds to element in the
Parameter Specification or Process Segment Parameter
Personnel Model
Equipment Model
Physical Asset Model
Material Model
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Work Schedule (part 4)
Work Schedule
Job List Work Request
+Made be made up of 0..*
1..* Work Master +Corresponds to Job Order
1..*
+May be made up of 0..*
+May be made up of 0..*
0..* Job Order Parameter
0..* Personnel Requirement
0..* Equipment Requirement
0..* Physical Asset Requirement
0..* Material Requirement
+Is assembled from 0..* 0..* Personnel Requirement Property 0..* Equipment Requirement Property 0..* Physical Asset Requirement Property 0..* Material Requirement Property
+Corresponds to element in 1 Personnel Model
+Corresponds to element in 1 Equipment Model
+Corresponds to element in 1 Physical Asset Model
+Corresponds to element in 1 Material Model
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Performance
What was made and what was used - example · A Operations Performance
Is a collection of Operations Responses
· A Operations Response
Is a collection of Segment Response Corresponds to a specific Production Request
· A segment Response
Correspond to a specific segment requirement Reports What resources were actually used, consumed, produced and other production data
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Operations performance (part 2)
Operations Definition
Operations Performance
Is made up of 1..n May correspond to a > 0..n 0..1
May correspond to an <
Operations Response
Operations Request
Is made up of May correspond to an < 1..n
Process Segment
Corresponds to a <
Segment Response
0..n
May contain
May contain
0..n
0..n
0..n
0..n
0..n
Segment Data
0..n May be made up of
Personnel Actual
Equipment Actual
Physical Asset Actual
Material Actual
0..n Is assembled from
1..n
1..n
1..n
1..n
Personnel Actual Property
Corresponds to element in
Equipment Actual Property
Physical Asset Actual Property
Corresponds to element in
Material Actual Property
Corresponds to element in
Corresponds to element in
Personnel Model
Equipment Model
Physical Asset Model
Material Model
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Work performance (part 4)
Work Performance
+May be m ade up of 0..* Work Response
+May be made up of 0..* +Is made up of 1..* Job Response Work Directiv e +Corrsponds to 0..1 +May be made up of 0..*
0..* +May be made up Job Response Data of 0..*
0..* Personnel Actual
0..* Equipment Actual
0..* Physical Asset Actual
0..* Material Actual
+Is assem bl ed from 0..* 0..* Personnel Actual Property 0..* Equipment Actual Property 0..* Physical Asset Actual Property 0..* Material Actual Property
+Corresponds to el ement in
0..*
+Correspondes to el ement in
0..*
+Correspondes to element i n
0..*
+Correspondes to element i n
0..*
1 Personnel Model
1 Equipment Model
1 Physical Asset Model
1 Material Model
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Segments, Segments, Segments...
· Process segment: manufacturing capability
Defines the manufacturing process available per segment Gather the required resources to execute the defined operations segments
· Operations/Work Segment: manufacturing requirements
Defines the specifications per operations segment Details the required resources for this operations segment
· Segment Requirement: run time requirements
Defines the specifics for an operations request
· Segment Response
Reports the actual happening
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Segments, Segments, Segments...
Operaitons / Work capability
Operations / Work definition
Operations segment ·Parameter ·Resource specification
Operations / Work schedule
Segment requirement ·Parameter ·Resource requirement
Operations / Work performance
Segment response ·Parameter ·Resource actual
Process segment ·Parameter ·Resource specification
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s n o i t a r e p O
s n o i t a r e p O i t a m r o f n I l u s r d n e k m o t a h W
Summary / part 2 e lb v is t a h W
m r o f n I y t l i b p a C e c r u o s R t l i y b a C p h W c u o s e r t a ilb v e r a t O o i a p s n r e t n m g e S y t l i b p a C o d e b n c t a h W u o s r e h it w c s e c o r P s t n m g e S s io c n u f t a h W ilb v e r a o s t n io t a r e p m f s n o i t a r e p O o t n i f e D t w o H an in t a r e p o m o f r e p s n o i t a r e p O l u d e h c S e b o is t a h W m s u & e d a s n t a r e io p O l u d e h c S
s n o i t a r e p O c n a m o f r e P s w t a h W s u & e d a m s n io t a r e p O c n a m o f r e P
May correspond to a
s n io t a r e p O y ilt b p a C
s n io t a r e p O o t in f e D
s n t a r e io p O t s u q e R
s n io t a r e p O n o p s e R
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Must correspond to a
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May correspond May correspond to a to a
s n io t a r e p O t n m g e S y ilt b p a C
s e c o r P t n m g e S
s n io t a r e p O t n m g e S
t n m g e S t n m ir u q e R
t n m g e S n o p s e R
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c r u o s e R y ilt b p a C
c r u o s e R y ilt b p a C
c r u o s e R S n o t a if c e p
c r u o s e R S n o t a if c e p
c r u o s e R m ir u q e t n R
c r u o s e R l a u t c A
May correspond to a
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May correspond to a
c r u o s e R y ilt b p a C P r y t e p o
c r u o s e R y ilt b p a C y t e p o r P
c r u o s e R S n o t a if c e p y t e p o r P
c r u o s e R n o t a if c e p S y t e p o r P
c r u o s e R t n m ir u q e R y t e p o r P
c r u o s e R l a u t c A y t e p o r P
108
m r o f n I y t l i b p a C Summary / part 4 e ilb v a s t h W
k r o W
c r u o s e R y t l i b p a C c u o s e r t a h W ilb v e r a
k r o W e t s a M r a C i b p t l y o d e b n c t a h W c u o s r e h it w y ilt b p a C k r o W
m f r e p t w o H
r k o W e t s a M r k r o w
e b o is t a h W d m o f r e P im t y b c u o s r & e
b o J t s i L
k r o W l u d e h c S e b o is t a h W d m o f r e P c n a m o f r e P
k r o W s w t a h W d m o f r e p v t c e r i D m f r e p t w o H b jo if c e p s a
k r o W
l u d e h c S
k r o W
d n p s e r o C
a o t
c n a m o f r e P
k r o W
t is L b o J
t s u q e R k r o W d n p s e r o C a o t
n p s e R k r o W
k r o W r e t s a M b p a C y ilt
d n p s e r o C a o t
k r o W r e t s a M
d n p s e r o C
a o t
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d n p s e r o C
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c r u o s e R n o t a if c e p S y t e p o r P
P M A a c y h t m ip u q E l, n o s r e
109
AGENDA
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
110
ISA95 part 5
· The Open Application Group OAG publishes an extensive XML schema specification for exhanging information to/from/between business systems (ERP)
www.openapplications.org It sometimes overlaps with ISA95
· Currently (04/2008) version 9.2, includes some ISA95 models · OAGIS defines messages based on a VERB-NOUN combination to properly handle complete transactions
Allowing Push/Pull/Publish-Subscribe transactional modes
· The ISA95 part 5 standard extend part 1/2 to specify applicable transactions/messages
It only use a subset of the OAGIS VBERBS
111
Messages et transactions
Message : · a structured Owner of information information unit conveyed in a oneLocal way transfer of data processing from one sending application to one or more receiving applications Transaction : SHOW · a sequence of related messages that are exchanged among applications
GET Equipment
Application Identification Area Data Area VERB = GET Noun = Equipment ID= "ABC"
User of information
GET
SHOW Equipment
Application Identification Area Data Area VERB = SHOW Noun = Equipment ID= "ABC" Description = "Simple equipment" Equipment Property ID = "Throughput" Value = 200 PPM Description = "Throughput as parts per minute" ...
112
Message Structure
· Content of a message: Application identification area
typically includes the electronic address of the sender, an indication of the confirmation requirement, and the date and time the message was created ...
Message Application Identification Area Data Area VERB NOUN
Data Area VERB
defines the action to be performed, or the response to a request
Data Area NOUN
represents one or more objects, as defined in the Part 1 and Part 2 object models
·
The above information defines a unique and unambiguous meaning of messages
113
Verb list
Verb ACKNOWLEDGE CANCEL CHANGE CONFIRM
Description Acknowledgement of a PROCESS request. Request to a receiver to remove information. Request to a receiver to change information. Confirmation response to a request.
Model PUSH PUSH PUSH PUSH, PULL PUBLISH PULL PUSH PUSH PULL PUBLISH PUBLISH PUBLISH
GET PROCESS RESPOND SHOW SYNC ADD SYNC CHANGE SYNC DELETE
Request to a receiver for information on one or more objects. Request to a receiver to process new information. Response to a CHANGE message request. Response to a GET message. Request from the owner of the object to add information Request from the owner of the object to change information Request from the owner of the object to delete information
Noun list
Personnel Class Person Qualification Test Specification Equipment Class Equipment Equipment Capability Test Specification Physical Asset Class Physical Asset Physical Asset Capability Test Specification Material Class Material Definition Material Lot Material Sublot Material Test Specification Resource Relationship Network Connection Type Resource Relationship Network Connection Process Segment Operations Capability Work Capability Operations Definition Work Directive Work Master Workflow specification Operations Schedule Work Schedule Job list Operations Performance Work Performance Work Alert Transaction Service Profile
Agenda
· · · · · Example Methodology ISA95 part 2&4 models ISA-95 par 5 B2MML
116
Overview
· The ISA95 object models may be used as the basis for formalized information exchange protocols
Such as SQL tables, XML internet files, or IDL object definitions
· B2MML is originally an XML implementation of ISA95
Along with BatchML for ISA88
· B2MML = ISA88+ISA95 data structures implementation
BatchML (ISA88 part 2) and new ISA88 models (Part 3 and 4) are now merged into B2MML
· B2MML is developed by the WBF
WBF is an ISA sponsored/supported organization B2MML is for "Business To Manufacturing Markup Language" Has become the de facto implementation standard for business to manufacturing information exchange
· B2MML benefit of a reactive development environment
About 1 version / year
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Example: Personnel schema
Information About Personnel Classes Information About Tests Information About Persons
Personnel Class
Has properties of >
0..n 0..n Is tested by a > 0..n
0..n < Defined by 0..n Is tested by a > 0..n
Person
Has values for >
Qualification Test Specification
0..n Is tested by a > 0..n Defines a procedure for obtaining a > 0..n < Maps to 0..n < Records the execution of 0..n
Qualification Test Result
0..n
Personnel Class Property
Person Property
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Example: Personnel schema - Header
119
Extension mechanism
120
Example: Personnel schema root element
121
Download the latests
· This presentation (and many others)
http://www.syntropicfactory.com/node/3798
· B2MML
http://wbforg.affiniscape.com/displaycommon.cfm?an=1&subarticlenbr= https://services.mesa.org/ResourceLibrary/ViewCategory/8c65bee5-db
· ISA95 committee
http://www.isa.org/isa95
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Thank You j.vieille@controlchaingroup.com www.syntropicfactory.com www.controlchaingroup.net
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Johann Sebastian Bach. the music closest to silence, closest, in spite of its being so highly organized, to pure, one-hundred-degree proof Spirit" (Aldous Huxley, Island)