This work is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License. Attribution: Jean Vieille Work: ISA8895 Implementation Section: Function Chapter: Operations Management Language: English Version: V3 - 05/2011 Jean Vieille www.syntropicfactory.info j.vieille@syntropicfactory.info Research community www.controlchainmanagement.org Consulting group www.controlchaingroup.com Agenda Introduction ISA95 Operations Activity Model (Production example) Operation Processes / Task definition 3_40_ISA8895_Function_OperationsManagement 2 CC functional domains ISA88 ISA95 3_40_ISA8895_Function_OperationsManagement Product Asset Management Inventory Asset Management Physical Asset Management Human Asset Management TOGAF ITIL ISA88 + ISA95 3 IT Asset Management Information Elements Cliquez pour ajouter Stdtableau un Domain sur l'icôneModel Information elements Product Asset Inventory Asset Physical Asset Human Asset Equipment Control Physical Process Control Physical Process Mngt Operation Process Mngt Product Product Material Physical Equipment Personnel Procedural Procedural Segment Operation Activity ISA88 ISA95 ISA95 ISA88 ISA95 ISA95 ISA88 ISA88 ISA95 ISA95 Product Hierarchy Product Definition Material Resources Equipment Hierarchy Equipment Resources Personnel Hierarchy Personnel Resources Functional Hierarchy Equipment Procedural Elements Physical Processes / Procedural Elements Physical Process Transform Components Segments Operation Processes Activities / Tasks 4 3_40_ISA8895_Function_OperationsManagement Who's / What's concerned? PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau X X R X Typ.IT app Customer order processing Production planning & scheduling Production control Material and energy control Procurement Quality assurance Product inventory control Product cost accounting Product shipping administration Maintenance management Research & development Engineering X X X X 3_40_ISA8895_Function_OperationsManagement 5 Operations Process Management Domain OPM typically corresponds to most of the ISA95 part 3 activity model However, ISA95 is unclear around the "Execution Management" bubble Ø This mirror the current confusion about what is done in control systems and MES Ø Sometime "Automated" actions are handled by control system, while manual actions are handled by MES... Basically, OPM deals with Management, not Control: Ø It must not be constrained by Real Time focus § Asynchronous Execution - If a task's completion is requested to move forward the physical process with impact on work throughput, it must be handled by the Physical Process Control level (Recipes / Operating procedures...) Asynchronous Definition - A new product generally not lead to define new Operation processes Ø It is typically not product dependent § 3_40_ISA8895_Function_OperationsManagement 6 OPM domain For example: Ø Dispatching instruction for working on a particular work station is part of an OP § It is clearly defined in ISA95 part 3 activity model § It is done early enough to allow a delay in task's completion Ø Identifying a material to be added, § Forbidding the use of the material or making the production not acceptable if not completed upfront will make the function part of Physical Process Control, not a BP task § Being required only for information / reporting purpose make this function possibly handled as a BP Task. Basically, no conceptual difference between Ø OP/Task (Management) Ø RPE/EPE (Control) Ø Company specific policies must be set 3_40_ISA8895_Function_OperationsManagement 7 Generic Activity model 1.Detailed scheduling 8. Resource management 2.Dispatching 7.Definition management 3.Execution Management 4.Data collection 5.Tracking 6.Analysis Source: ANSI/ISA 95 Enterprise/Control System Integration 3_40_ISA8895_Function_OperationsManagement 8 Different MES Focus 1. 2. 3. 4. Decisional focus Ø Business / Execution Ø Decisional / Physical Hierarchy : Work station, Work cell, Area, Site, Enterprise... Operational Responsibility focus Ø Manufacturing, Inventory, Quality, Maintenance... Timing focus Ø Before, during, after work execution Maturity focus Ø Visibility, Control, Optimization 3_40_ISA8895_Function_OperationsManagement 9 (1) Decisional focus : MES Domains and Functions Order Processing (1.0) Business Responsibility Domain Production Scheduling (2.0) Product Cost Accounting (8.0) Product Shipping Admin (9.0) Execution Responsibillity Domain Material and Energy Control (4.0) Production Control (3.0) Product Inventory Control (7.0) Procurement (5.0) Quality Assurance (6.0) Maintenance Management (10.0) Marketing & Sales Research Development and Engineering Source: ANSI/ISA 95 Enterprise/Control System Integration 3_40_ISA8895_Function_OperationsManagement 10 (1) Decisional focus : Hierarchy according to ISA95 ENTERPRISE SITE AREA Work Center Work Unit 3_40_ISA8895_Function_OperationsManagement 11 (2) Operational responsibility focus : Domains according to ISA95 Order Processing (1.0) Product Cost Accounting (8.0) Product Shipping Admin (9.0) Production Scheduling (2.0) PRODUCTION OPERATIONS MANAGEMENT Production Control (3.0) INVENTORY OPERATIONS MANAGEMENT Material and Energy Control (4.0) INVENTORY OPERATIONS MANAGEMENT Product Inventory Control (7.0) QUALITY OPERATIONS MANAGEMENT MAINTENANCE OPERATIONS MANAGEMENT Maintenance Management (10.0) Procurement (5.0) Quality Assurance (6.0) Marketing & Sales Source: ANSI/ISA 95 Enterprise/Control System Integration Research Development and Engineering 3_40_ISA8895_Function_OperationsManagement 12 (2) Operational responsibility focus : Beyond Production Manufacturing Operation Categories (MOCs) in ISA95: Ø Production Ø Quality tests Ø Maintenance Ø Inventory control Other possible MOCs : Ø Distribution, Transportation Ø Inbound, Outbound logistics Ø Internal transfers Ø Tooling Ø Cleaning Ø ... 1.Detailed scheduling 8. Resource management 2. Dispatching 7. Definition management 3. Execution Management 4. Data collection 5. Tracking 6. Analysis 3_40_ISA8895_Function_OperationsManagement 13 (3) Timing focus Before operation execution Ø These activities are performed before Production occurs During operation execution Ø These activities are performed while production continues § Real time interaction After operation execution Ø These activities are performed § After Production has been completed § While Production is performed, but not synchronously Not time related Ø These activities are performed independently of production § Provide necessary information for production § May be affected by production (resource status and usage) 3_40_ISA8895_Function_OperationsManagement 14 (3) Timing focus MES Main Functional areas Pre-Work Reference data Resource Management Detailed Scheduling Tracking Dispatching Analysis Post-Work Definition Management Actual Work Execution Management Data collection 3_40_ISA8895_Function_OperationsManagement 15 (3) Timing focus : Main activity flows Detailed Scheduling Resource Management Tracking Analysis Data Collection Dispatching Definition Management Execution Management 3_40_ISA8895_Function_OperationsManagement 16 (4) Maturity level Visibility: Ø Data collection, performance monitoring, reporting Control: Ø Work Specification enforcement, Ø Quality control, Ø Operation conformance against defined practicies Optimization, anticipation: Ø Statistic or Real time process improvement Ø Resource usage optimization Ø Performance objectives and improvement processes against strategic criteria 3_40_ISA8895_Function_OperationsManagement 17 Agenda Introduction ISA95 Operation Activity Model (Production example) Operation Processes / Task definition 3_40_ISA8895_Function_OperationsManagement 18 Applying the Generic Activity model to Production MOC Can be applied to: · Inventory · Quality Control · Maintenance · +... Production resource management Detailed production scheduling Production tracking Production dispatching Production Analysis Production data collection Product definition management Production Execution Management 3_40_ISA8895_Function_OperationsManagement 19 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 1. Detailed Production Scheduling (Before) Production Plan Generation Ø At a level of detail below corporate planning Finite capacity scheduling Ø Recognize alternative and parallel operations & exact timing Production Schedule Production Schedule Production Schedule Resource Information Detailed Production Scheduling Resource Information Detailed Production Scheduling Detailed Detailed Production Detailed Production Schedule Production Schedule Schedule Detailed Production Schedule 3_40_ISA8895_Function_OperationsManagement 20 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 2. Production Dispatching (Before) Detailed Production Schedule Production Dispatching Setup Machine Produce Batch Move Ticket Managing flow of production by dispatching work Ø Work orders/Batches to work units Ø Material movement request Download automatically in response to the schedule or on request Ø Recipes/Routings to equipment Ø Work instruction, SOP, drawings or electronic data to work stations Continuous Premix Batch Production Process Material Movement 3_40_ISA8895_Function_OperationsManagement 21 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 3. Production Execution (During) May be manual or automated Includes Ø operators actions based on instructions dispatched to operators Ø automated actions through control systems 3_40_ISA8895_Function_OperationsManagement 22 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 4. Production Data Collection (During) Collecting operational data Ø Production and parametric Ø Associated with production equipment and production processes Concerns Ø sensor readings, equipment states, event data, operator entered data, operator actions, and everything of importance in the making of a product or analysis of products, processes, or production Includes Ø Real time data collection Ø History of production data § Addressed in ISA88 part 4 3_40_ISA8895_Function_OperationsManagement 23 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 5. Production Tracking (After) Track actual production and performance to the production plan Information transferred back to scheduling so that plans & schedules can be updated Monitor and track the status of production Data reconciliation Ø Consolidate production information Genealogy/Product Traceability Ø Collects, prepares and provides material transformation and relationship information to inventory management systems 3_40_ISA8895_Function_OperationsManagement 24 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 6. Production Analysis (After) Product analysis Ø product quality control, SPC / SQC tracking Ø In-Line control by operations staff Ø off-line inspection & analysis in Laboratory Information Management Systems (LIMS) § Addressed by Quality Operation MOC Process analysis Ø Analyses and optimizes physical process performance regarding Product quality and variability Production analysis Ø Analyses and optimizes production performance regarding Cycle times, Resource utilization, Procedure efficiencies, and Production variability 3_40_ISA8895_Function_OperationsManagement 25 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 7. Product Definition Management (Reference data) Manage recipes, work instructions, Product production rules, Product segment Ø Synchronize this information with other systems General/Master Recipes, Product / process segments mapping Ø (alt. Resource management) 3_40_ISA8895_Function_OperationsManagement 26 Detailed production scheduling Production resource management Production dispatching Product definition management Production execution Production data collection Production tracking Analysis 8. Resource Management (Reference data) Personnel management Ø Maintain personnel Attendance, availability, status, location, exposure qualification information ... Material management Ø Inventory operations, relationship with MM systems Ø Mostly addressed by Inventory Operation MOC Equipment management Ø Maintain equipment status,location, availability Ø Relationships with LIMS, Asset Management, Maintenance Management, Production Planning, Mostly addressed by Maintenance Operation MOC Process Segment management Product / Process segment, General/Master recipes mapping Ø (alt. Product definition) Production capability 3_40_ISA8895_Function_OperationsManagement 27 Applying the Activity model to other MOCs Inventory Quality Control Maintenance +... 3_40_ISA8895_Function_OperationsManagement 28 Supporting functions These functions provide Ø Suitable technical framework Ø Global services and procedures Ø Not directly linked to Production's main purpose 3_40_ISA8895_Function_OperationsManagement 29 Supporting Functions: McDo model Detailed work scheduling Work resource management Work dispatching Work tracking Work Performance analysis Work data collection Work Execution Management Management of regulatory compliance layer Operational activity level Management of security layer Management of documents layer Management of Configuration layer Management of Incidents & deviations layer Work definition management Management of information layer 3_40_ISA8895_Function_OperationsManagement 30 A Tridimension functional framework Manufacturing Operation Categories Production Maintenance Quality Inventory ... Manufacturing Operation Core Functions Detailed Scheduling Dispatching Execution Management Data Collection Tracking Analysis Definition Management Resources Management Operation Processes Functional Requirements (Tasks) Execution/Manufacturing Supporting activities Management of security Management of information Management of configurations Management of documents Management of regulatory compliance Management of incidents and deviations Business/Planning 3_40_ISA8895_Function_OperationsManagement 31 Agenda Introduction ISA95 Operation Activity Model (Production example) Operation Processes / Task definition 3_40_ISA8895_Function_OperationsManagement 32 Terminology Operation Process, Activity, Task Ø ISA95 uses the term of "Activity" for the main breakdown of its "activity model". Ø It further details these activities into "Tasks", which are the appropriate level for functional requirements. Ø ISA95 Activity is a task classifier Ø ISA95 ignores Operation Processes. Ø BPM standard terminology uses Activity in the sense of ISA95 Tasks CCM uses the terms Ø Operation Processes Ø Activity as a Task classifier (consistent with ISA95) Ø Tasks (in the ISA95 sense), 3_40_ISA8895_Function_OperationsManagement 33 Iterative OP/Task Definition OP Identification OP Design/Task Id Task Description Operation Processes Tasks Task Classification 3_40_ISA8895_Function_OperationsManagement 34 Operations Processes BP Identification BP Design/Task Id Task Description The highest level in the Control Chain They define Ø Operation contexts Ø Task (functional services) activation scenarii / orchestration applicable in these situations They can be: Ø Manual Ø Automated Ø Assisted They can be hierarchical: Ø High level processes trigger lower level processes Ø Elementary processes are Tasks Task Classification 3_40_ISA8895_Function_OperationsManagement 35 Operations Process Classification BP Identification BP Design/Task Id Task Description 1. Execution Management Ø Concerns directly the organization, the launch and the follow-up of work execution Ø Specific to MOC or shared by several MOCs § Example : Scheduling of production 2. Resources Management Ø Concerns activities related to resources, but not directly to work orders § Example : Monitoring employee qualifications, follow up of equipment performance, of material obsolescence ...; Genealogy, equipment and personnel performance 3. Global Operations Management Ø Dashboards, performance indicators not directly related to work orders Ø Activity reports per shift/day/week/year 3_40_ISA8895_Function_OperationsManagement 36 Task Classification Operations Process Classification BP Identification BP Design/Task Id Task Description 4. Definition/Synchronisation of Master Data Ø Concerns maintenance of technical data (Products, resources) § Example: Conception of a new product, involving synchronized processing at management and execution systems level The classification strongly depends on management options Ø The conception of a product could be integrated in the execution management (dynamically) or in synchronization of master data (statically) depending on the instances Task Classification 3_40_ISA8895_Function_OperationsManagement 37 Operations Process Design: BPMN Language BP Identification BP Design/Task Id Task Description Developed by BPMI www.bpmi.org www.waria.com ) Ø Business Process Management Initiative / Workflow and Reengineering International Association Ø Member du Workflow Coalition W3C, OASIS, OAG, WFMC Task Classification 3_40_ISA8895_Function_OperationsManagement 38 Business Process Design : BPMN Language BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 39 Business Process Design : BPMN Language BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 40 Business Process Design : BPMN Language BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 41 Example 3_40_ISA8895_Function_OperationsManagement 42 Task Identification BP Identification BP Design/Task Id Task Description The definition of operation processes in the preceding steps allows to build the list of tasks handled by these processes. The tasks are defined and organized within the activities of ISA95-3 models The following steps will modify this list by rapprochement, consolidation, "objectification" Ø The operation processes will be arranged to take into account the tasks actually defined Ø These 2 steps are thus carried out in a simultaneous and iterative manner. Task Classification 3_40_ISA8895_Function_OperationsManagement 43 Tasks Description BP Identification BP Design/Task Id Task Description The description of tasks includes 3 types of information: 1. The Characterization which defines the attributes of use and justification of the task 2. The Informational / Interface Requirements which links tasks to handled information 3. The Functional Requirements which defines the services expected from the task Only the first type is considered here. The Informational / Functional requirements are discussed in CCM4 Information Service Specification Task Classification 3_40_ISA8895_Function_OperationsManagement 44 (1) Tasks Characterization Characteristic 1. Decisional applicability 1. MOC 2. Usage Level 3. User Profile 2. Restrictions 3. Typology 1. IT Service Levels 2. Style of processing 4. Dependency Description BP Identification BP Design/Task Id Task Description Task Classification - Relative Manufacturing Operation Categories - Applicable Physical/decisional level (Area, Work Centre, Work Unit...) - Personnel Classes involved in the execution of the task (access to the system) Applicable Segment, Personnel, Material, Equipment (resources) - What are the technical constraints (>>) - The type of information processing the task fulfils (>>) Other necessary tasks in order to implement this one. The dependences can "technically" impose tasks considered not to be economically profitable 3_40_ISA8895_Function_OperationsManagement 45 (1) Tasks Characterization ­ Example of IT Service Levels Cliquez sur l'icône pour ajouter un tableau Criteria IT Service Level Data Synchronism Data Acquisition Cycle time Calendar of opening System availability Data integrity Environment « Control » Synchronous Real Time 6D/7 24H/24 Very high Average Industrial Exemple of criteria value per type « Operation » Synchronous and Asynchronous < 5 seconds 6D/7 24H/24 High Very high Semi-industrial « Business » Asynchronous N/A 5D/7 8H/24 Average Very high Office BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 46 (1) Tasks Characterization Processing Style # Type Description Cliquez sur l'icône pour ajouter un tableau RT TS ST KM AN MD CL WF Real Time Transactional Data Storage Knowledge Management Analytical Modelling and simulation Collaborative Workflow BP Identification BP Design/Task Id Task Description Task Classification Interaction with the process or the operator which directly impacts the production (normally excluded from the field of BPM) Involves data requiring a high level of precision and reliability Collection, selection, consolidation, validation of information for purposes of later use Shaping of the collected information to facilitate and improve the operations Information Analysis to help in decision-making. Can be coupled with manufacturing process or quality assurance Asynchronous preparation processes of a principal activity, such as scheduling Connects independent activities and responsibilities for obtaining a common objective (non-structured) Connects activities in a preset and structured manner 3_40_ISA8895_Function_OperationsManagement 47 (2) Information BP Identification BP Design/Task Id Task Description Task Classification The informational dimension of ISA95-2 can be introduced under 3 angles: Ø To associate each task to models and objects of data used (inputs) and affected (outputs) § Allows logical regroupings of tasks Ø Particular information which the user needs § Data presented / entered Ø Contents of the publishing relating to the task § Reports, labels, delivery order... This sets a basis for standardized Information Service framework Ø Enforcing independence of solutions Ø Enabling SOA architectures The following slides list the ISA95 data objects Ø They are modified / generalized to apply to all MOCs Ø See ISA95 part 2 for details of object attributes 3_40_ISA8895_Function_OperationsManagement 48 (2) Information BP Identification BP Design/Task Id Task Description Task Classification MOC MOC Activity Activity T T T T T T T T Mod/Ob j Data Mod/Ob j data Mod/Ob j data Mod/Ob j data Mod/Ob j data 3_40_ISA8895_Function_OperationsManagement 49 (2) Information ­ Generalized ISA95 model objects Capability l'icône pour ajouter un tableau Work capability Cliquez sur Model Personnel capability Personnel capability property Equipment capability Equipment capability property Material capability Material capability property Work segment capability Segment personnel capability Segment personnel capability property Segment equipment capability Segment equipment capability property Segment material capability Segment material capability property BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 50 (2) Information ­ Generalized ISA95 model objects Personnel Person Cliquez sur l'icône pour ajouter un tableau Model Person property Personnel class Personnel class property Qualification test specification Qualification test result Equipment Model Equipment Equipment property Equipment class Equipment class property Equipment capability test specification Equipment capability test result BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 51 (2) Information ­ Generalized ISA95 model objects Material Model Material class Cliquez sur l'icône pour ajouter un tableau Material class property Material definition Material definition property Material lot Material lot property Material sublot QA test specification QA test result Segment model segment Personnel segment specification Personnel segment specification property Equipment segment specification Equipment segment specification property Material segment specification Material segment specification property 3_40_ISA8895_Function_OperationsManagement BP Identification BP Design/Task Id Task Description Task Classification 52 (2) Information ­ Generalized ISA95 model objects Schedule l'icône pour ajouter un tableau Schedule Cliquez sur model Request Segment requirement Parameter Personnel requirement Personnel requirement property Equipment requirement Equipment requirement property Material requirement Material requirement property BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 53 (2) Information ­ Generalized ISA95 model objects Performance l'icône pour ajouter un tableau Performance Cliquez sur model Response Segment response Data Personnel actual Personnel actual property Equipment actual Equipment actual property Material actual Material actual property BP Identification BP Design/Task Id Task Description Task Classification 3_40_ISA8895_Function_OperationsManagement 54 (3) Functional Requirements BP Identification BP Design/Task Id Task Description The behavioural description of the tasks is declined under following headings: Ø Description of the normal behaviours Ø Description of exceptions Ø Description of behaviours on exceptions The level of detail will evolve during the project, Ø the initial indications can be limited to the constraints and provisions specific to the business and the company Ø The implicit requirements will be completed during the course of realization See example of description sheet Task Classification 3_40_ISA8895_Function_OperationsManagement 55 Classification of the tasks BP Identification BP Design/Task Id Task Description The task carries the detail of the functional requirements, Ø the ISA-95-3 activities constitute an element of classification § Task Classification The standard provides rather complete indications on the scope of the tasks within an activity. The tasks are described without concern on their implementation on a target system. The tasks defined during the preceding steps are the fruit of a reflexion by category of exploitation Ø In reality, some tasks are in common, are shared or similar and must thus consequently be brought together to offer a consistent breakdown We obtain a reduced and more consistent task list. Ø The functional descriptions and elements of characterization are amended if necessary (Iteration) Ø This step leads to a classification of these reusable business object tasks within the company Ø 3_40_ISA8895_Function_OperationsManagement 56 Multipurpose tasks BP Identification BP Design/Task Id Task Description The same task is defined for independent operation contexts Ø only one specification Ø Deals only one MOC at a time: independent data bases and users Examples: Ø Tasks involved in Work Definition Management can be handled by the same application using different databases. Ø Analogy: MS Office Task Classification The same task applies to several MOCs 3_40_ISA8895_Function_OperationsManagement 57 Specific Tasks BP Identification BP Design/Task Id Task Description The task is specific to a MOC Ø tasks fulfilling similar roles in other MOCs are different Examples: Ø Tasks involved in executing a production or a maintenance order require significantly different functional capabilities Ø analogy: Ms Project, SAP APO Task Classification The task is specific to the MOC 3_40_ISA8895_Function_OperationsManagement 58 Common tasks BP Identification BP Design/Task Id Task Description The task handles problems for several MOCs globally. Example: Ø Tasks involved in Resource Management can be ensured in a centralized manner Ø Analogy: human resources management Task Classification The task covers several MOCs 3_40_ISA8895_Function_OperationsManagement 59 Exercises: Model Operation Management ­ Excel spreadsheet (1.1) Define / Discuss Operation Process Categories (1.2) Define / Discuss Manufacturing Operation Management Categories (1.3) Define / Discuss Operation Activities (1.4) Define / Discuss IT Service Level (1.5) Define / Discuss Operation Task Styles (2.1) Define Operation Process Classes (2.1) Define / Consolidate Task Classes (3.1) Instantiate Operation Processes on an actual facility 3_40_ISA8895_Function_OperationsManagement 60