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This work is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License. Attribution: Jean Vieille
Work: ISA8895 Implementation Section: Structure Chapter: Knowledge Asset
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 ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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CC functional domains
ISA88 ISA95
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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
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Objective of the Knowledge Asset Modelling
The value of a product is set by the need of the market to own it Its manufacturing implies the combination of other products and their transformation The industrial solution to make the product is built on the specification of material combination and physico-chemical transformation required to obtain a congruent product Ø It basically defines the value creation stream of the product Ø Several « synthesis routes » can be defined Product Asset Modelling handles this specification that Ø Enables the product industrialization Ø Decouples the product value creation stream and the operating procedure (See « From Product to Process »)
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Objective of the Product Asset Modelling
Product Modelling provides an abstraction of the physical-chemical processing Ø It is independent of facilities physical layout and machinery capabilities Ø Variant of the same product definition may exist for different sites It highlights necessary material transformations to obtain the desired product Ø The Energy Chain primitive breakdown It is shared by all parties of the Money and Energy Chains Ø Provides a basic, consistent framework for benchmarking manufacturing segment between product, facilities and batches / production runs Ø Must correspond to a specific level of Product Segment: bi-directional Design (PLM) / Supply Chain integration
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Who's / What's concerned?
PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau 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
Material identification and equivalence
X
Determine quality criteria and protocoles
X
Production costing
R
Response to market, industrialize products
Build/adapt manufacturing facilities 2_40_ISA8895_Structure_ProductAsset
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Models Overview
This asset is described in a hierarchical manner 4 models address knowledge asset modelling Ø ISA88 Product Hierarchy Model § Called "Process model" in ISA88 Ø ISA95 Process Segment model Ø ISA95 Operations Definition model Ø ISA88 Equipment Independent Recipe Model § See « From Product to Process »
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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ISA88 Product Hierarchy Model
Addresses to the structural description of the company product knowledge asset Ø Hierarchical transformations to obtain a product Highly flexible, not constraining, Ø The hierarchy can be adapted: extended, collapsed, renamed Ø The "Batch taste" terminology can be adapted Ø Supports convergent / divergent processes Independent of the facility Ø No relationship with Physical Asset Ø Focuses on material transformation / combination Ø =/ equipment related operating procedure Ø Neutral basis for performance benchmarking
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ISA88 Product Hierarchy Model
Process Procedure
Process Elements
Process Stage
A sequence of chemical, physical, or biological activities for the conversion, transport, or storage of material or energy.
·
A part of a process that usually operates independently from other process stages and that usually results in a planned sequence of chemical or physical changes in the material being processed.
·
Process Operation
A major processing activity that usually results in a chemical or physical change in the material being processed and that is defined without consideration of the actual target equipment configuration.
·
Process Action
Minor processing activities that are combined to make up a process operation.
·
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Process Definition
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
The hierarchical sequence of process stages, process operations PROCESS and process actions that defines an ideal procedure for the ACTION manufacture of a successful product. Ø Specific rework processes can be defined as separate Process Procedures Inputs Ø Raw materials, purchased products Ø Intermediate products Ø Energy Outputs Ø Intermediate products Ø Co-product, by-products, Ø Energy
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Process Stage
PROCESS PROCEDURE PROCESS STAGE
A major transformation activity / a main product breakdown Ø a sequence of process operations = chemical or physical changes in the PROCESS ACTION material being processed Ø Independent: produces stable intermediate products Ø For the product production information / planning / supervision / process engineering Definition based on Ø Chemistry / Physics Ø Logistics Ø Engineering Inputs Ø Raw materials, purchased products Ø Intermediate products Ø Energy Outputs Ø Intermediate products: not necessarily identified from on PS to another Ø Co-product, by-products, Ø Energy 2_40_ISA8895_Structure_ProductAsset 13
PROCESS OPERATION
Process Stages definition rules
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Product physico-chemichal status Ø Chemical synthesis route Ø Main parts manufacturing and main assembly steps Major transformation Ø Obvious change in the nature or shape Combination / Separation Ø Based on convergence/Divergence points Intermediate Ø Independent / Asynchronous / Managed Ø Usable for several products Ø Can be sold as finished product Ø Can be sourced from external vendors
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Process Stages definition rules
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
Target facility PROCESS Ø Common equipment constraints for the process stage ACTION Ø Alignment on existing Work Center (Process Cell): The Process Stage corresponds to one or several Master Recipes Intermediate products planning Ø Within or separately of the finished product Ø Process Stage = Process Procedure for an intermediate Ø Planning of an intermediate: the Process Procedure contains the only corresponding Process Stage
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Process Operations
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
A major transformation activity PROCESS Ø A sequence of Process Actions ACTION Ø Operate in sequence on the material within the process stage Ø Irreversible chemical or physical change in the material being processed Ø Generally based on chemical or physical considerations Inputs Ø Raw materials, purchased products Ø Intermediate products Ø Energy Outputs Ø Intermediate products: not necessarily identified from on PS to another Ø Co-product, by-products, Ø Energy
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Process Operations definition rules
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
Natural organizational structure to identify major processing steps PROCESS Ø Obvious processing steps ACTION Ø Test and decision points Alignment to Master Recipes Ø Identification of possible operation boundaries for subsequently generated master recipes Equipment requirements identification for actions within the operation Supervision requirement Ø Long process breakdown Ø Finer granularity for manufacturing performance monitoring & benchmark
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Process Action
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
A basic processing activity, PROCESS Ø like grind, cool, heat, delay, test or mix ACTION Ø Addition or removal of material or energy, setting environment Process Actions within the operation Ø Operate on the defined materials in a defined sequence that may be serial / parallel / contain multiple branches Inputs / Outputs Ø Normally no product related I/O identified for Process Action § However, Process Actions act on Operation I/O Ø Processing Parameters and Processing Data
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Process Action Rules
Process Actions can be of different types. For example: Ø Material addition can be a fixed rate or controlled by a process variable such as a pressure, temperature, or pH Company specific process actions Ø unique company processing capabilities (separation, packaging...) Industry specific process actions, Ø such as catalytic conversions or property state changes.
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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ISA88 Equipment Independent Recipe Model
ISA88 defines 2 categories of recipes Ø EIR: Equipment Independent Recipes (General, Site) define how to manipulate materials to make a product Ø EDR: Equipment Dependent Recipes (Master, Control) specifies how to control equipment in order to make a product The Product Hierarchy based EIR Ø Describes the processing requirements § as a flow of material combinations and transformations Ø Identifies the produced and incorporated materials, parameters Ø Specifies the constraints applicable to the manufacturing equipment not the equipment itself Ø Supports the requirement specification to develop the operating procedure applicable to a particular facility § Complete, consistent, unambiguous § Understandable by R&D and engineering, at corporate and local levels
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ISA88 Equipment Independent Recipe Model
ISA88 Part 3 Extends the General/Site Recipe description in Part 1 Provide a standard way to maintain and exchange general recipes Ø Foreign plants, Contract manufacturing Developed collaboratively Ø Based on shared definition of processing capabilities, material master, equipment constraints Ø Within the enterprise and among its partners in manufacturing Ø Multiple different control system suppliers, integrators, and consultants
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ISA88 Equipment Independent Recipe model
EIR Recipe Process Product hierarchy "Process model" Process Stage Header Formula Equipment Constraints Other Information
From ISA-88 Part 3 Draft 13
Process Operation
Process Action
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Header
The administrative information in an equipment independent recipe is referred to as the header May include such items as Ø Recipe identification Ø Version number Ø Product identification Ø Product family Ø Product grade Ø Originator Ø Lifecycle state
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Formula
Includes Ø Process inputs Ø Process parameters Ø Process outputs Process inputs and process outputs identify Ø Materials and quantities of materials Ø Resources and quantities of resources § (Energy, ...)
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Formula: Material
Materials used in equipment independent recipes shall be identified by material definitions or material classes as defined in the ANSI/ISA 95.00.01 standard Ø Equipment independent recipes do not use material lot definitions Material definitions and material class definitions should be maintained in a material definition library to ensure that only valid material definitions are used in equipment independent recipes A material definition shall have an associated lifecycle state
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Formula: Relationship with the Inventory Asset Model
A material can correspond to an output of a particular Process element Ø A finished Product is the result of a Process Definition Ø An intermediate can be the result of a Process Stage or possibly of an operation Product Hierarchy level as Material Classes Ø Process Definition / Stage / Operation can be value for the class "ProductHierarchyLevel" = ProcessDefinition / ProcessStage / ProcessOperation Product Hierarchy level as Material Property Ø Process Definition / Stage / Operation can be value for the Property "ProductHierarchyLevel" = ProcessDefinition / ProcessStage / ProcessOperation
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Formula: Parameter
Correspond to ISA-95 Operations segment parameters
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Equipment Constraints
Equipment Constraints are a statement of the specific requirements of the final manufacturing equipment necessary to bring about the process activities May also document certain important attributes to select the suitable equipment needed in this process Used when the equipment properties may impact the chemistry or physics of production Used to define "hints" to manufacturing where R&D knows the properties of the material will cause problems if not carefully handled Equipment constraints correspond to ISA-95 Equipment specification properties in ISA-95 Operations segment model
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Example of Equipment Constraints
Constraint
ExternalHeatingCoils
Description
Specifies if any heating coils are external to the containing vessel, so they cannot be fouled by the batch material. Specifies if the containing vessel is glass lined and connecting pipes are Teflon lined. Specifies if the containing vessel and pipes are free of any elements containing nickel. Specifies if any transfers between vessels are short, so that unintended reactions (such as crystallize) will not occur in the piping. Specifies if any transfers between vessels are relatively straight, so that highly viscous or material prone to plugging may be transferred. Specified that the agitation method does not shear the batch material.
Constraint Type TRUE or FALSE TRUE or FALSE TRUE or FALSE TRUE or FALSE TRUE or FALSE TRUE or FALSE
LiningGlass
LiningNickelFree
TransfersShort
TransfersStraight
AgtitationNonSheared
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Other Information
A general recipe is a container of production information required for manufacturing, but it may also contain information for other business activities Examples of other information that might be included with equipment independent recipes are: Ø Spreadsheets detailing known process sensitivity models Ø Complete process models Ø Pictures of good products Ø Pictures of bad products and possible failure reasons Ø References to Test Methods & Test Specifications Ø References to material data safety sheets Ø Additional health and safety information Ø Packaging information
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Process Action Information
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Process Action is the most detailed Process Element Ø Its definition is critical for linking R&D to Process Engineering
§
Product Definition to manufacturing capabilities § Basis for optimizing the transformation of the product definition into executable operating procedure / Recipe
Information elements:
Ø Ø Ø Ø Ø Ø Ø Ø
Functionality resulting from its realization Parameters to modify its behavior Information resulting from its execution Environment conditions for its execution Pre-conditions for its correct execution Post-conditions resulting of its execution to be taken into account Known Exception conditions Handling of these exception conditions
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Classes Of Process Actions
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
General actions deal with 1. Adding materials 2. Removing materials 3. Adding energy 4. Removing energy 5. Setting the environment (pressure, agitation...)
Company specific actions may PROCESS deal with unique ACTION 6. Material preparation 7. Material extraction 8. Material shaping 9. Material packaging 10. Material testing
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Examples Adding Material
Cliquez sur l'icône pour ajouter un tableau Process Action Functional Description Charge Parameters
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Add the specified material. There is no Material To Add rate constraint on the material addition. Amount to Add Usually used where there is no expected chemical reaction. Add the specified material at the specified rate and tolerance. Usually used when mixing is required or too fast a rate will cause an undesired chemical reaction.
ChargeAtRate
Material To Add Amount to Add Percent Per Minute % / Minute Tolerance Material To Add Amount to Add Maximum Temperature Minimum Temperature Temperature Tolerance
ChargeAtTemper Add the specified material so the ature temperature of the material being produced stays within the specified value. This can require heating or cooling capability. Usually used when an exothermic or endothermic chemical reaction will occur. 2_40_ISA8895_Structure_ProductAsset
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Examples Removing/Separating Materials
Process l'icône pour ajouter un tableau Cliquez sur Functional Description Action Dry Dry the material to remove any water or other safely evaporated materials. Parameters
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Material To Remove Expected Amount Removed Minimum Temperature Material To Remove Expected Amount Removed Evaporation Temperature Material To Remove Expected Amount Removed
Evaporate- Remove a solvent through evaporation. Solvent The solvent is to be retained and not dispersed into the atmosphere. FilterSolids Remove solids.
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Examples Adding Energy
Process Action pour ajouter un tableau Cliquez sur l'icône Functional Description Heat HeatProfile Induce energy to flow into the material. Parameters Final temperature
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Control the rate at which energy is Rate to heat added to the material. There can Holding temperature be one or many sets of Holding time parameters for different profiles.
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Equipment Independent Recipe Object Model
Why, Ø Because users wanted a standard way to maintain and exchange general recipes Ø To foreign plants Ø To contract manufacturing Ø To multiple different control system suppliers, integrators, and consultants The model Ø Does not define attributes § But it was enough to define a B2MML/BatchML XML exchange Ø Overlaps with ISA95 Product Definition Model § More dedicated, using ISA88 vocabulary
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EIR Object Model
Equipment Requirement Library
1..N
Is made up of
Is made up of
Process Element Library
1..N Is made up of
Equipment Independent Recipe
Has a type of
Material Definition Library
Is made up of 1..N
Equipment Requirement Element
1
Process Element Specification
1
General Recipe
1 1
Site Recipe
0..N
Material Definition
Corresponds 1 toÆ 0..N 0..N 1 Corresponds to Æ 0..N 0..N
May be derived from 0..N 0..N
Corresponds to Æ 0..N
Corresponds to Æ 0..N 0..N Has
Process Procedure
Is made up of 1..N
Other Information
0..N Has 0..N 1..N 1..N
Process Parameter
Process Input
0..N
Process Output
0..N
Equipment Requirement
0..N 0..N
Process Element
Has a type of
1
Process Element Link
Uses % of the input
1
Produces % of the output
Percent Input Process Action
Percent Output
Process Stage
1..N Is made up of
Process Operation
1..N Is made up of
From ISA-88 Part 3
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B2MML/BatchML implementation
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Handling General Recipe definition
Develop a standard corporate library of General Recipe elements Ø Material Definition Ø Equipment requirement definitions
These define what will be expected in final manufacturing equipment Each site can use this to determine how "capable" they are to meet R&D requirements § They describe to manufacturing sites exactly what equipment requirements will be asked for in production
§ §
Ø
Process actions definitions
Have manufacturing site determine its best manufacturing processes for each process action § These are used when creating master recipes § They describe to manufacturing sites exactly what processing they will be asked to perform to make products
§
They define a common language and provide a "contract" between manufacturing and R&D
Define all general and site recipes based on these standard definitions Ø Provide document management and change management of the definitions
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Summary
General and site recipes follow the same model as master recipes Ø Except they define a process not a procedure The standard includes guides to help identify the recipe elements (process stages, process operations, and process actions) Use of general and site recipes requires, as a minimum, libraries of process actions, materials, and equipment requirements Result will be faster and more reliable technology transfers
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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Equipment Independent Recipe Representation
Required within a company to standardize how they represent product definitions Ø Few companies have standard, formal, and unambiguous ways to describe pilot plant or R&D instructions to manufacturing ISA88 Part 3 defines the minimal representation method, Ø Graphical and table views defined Ø PFC for Process Function Chart
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General Recipe PPC (Process Procedure Chart)
7
Process Input representation (Material)
Nitration
2
Oxidation
13 8
22
Recipe annotation
Process Note: Make sure that process temperature is maintained between ring expansion and hydrolysis
Ring Expansion
55 1
12
Intermediate Material representation
Hydrolysis
10 2
Stage , operation, or action representation Process Output representation (Material)
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Graphical Recipe Representation
Use the material flow "PFC" notation within a Procedure Diagram Use SFC like notation within a Process Operation Diagram
Procedure Diagram Process Stage Diagram
M7
Process Operation Diagram
add wait
M7
M8
Premix
3
add
M8
Charge operation
Sterilize
2 8
add wait add
heat
wait add
mix hold
M9
Heat
9 2
M9
analyze
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Stage, Operation, and Action Graphical Representation
Rectangle represents a process stage, a process operation, or a process action The rectangle may be annotated
An identification Ø The number of underlying elements Ø The number of equipment requirements
Ø
Name
nn nn
Stage, Operation, or Action Name Stage, Operation, or Action Representation Indication on Underlying Elements Equipment Requirement Indication
12 04
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Material Representation
Materials are identified by arrows (directed lines) or arrows with circles
Process Input Representation Intermediate Material Representation
12
Any material may represent more than one material, with the addition of number inside the circle
Process Output Representation
Unidentified intermediate material
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Material Annotation
Materials may be annotated with the material ID May be annotated with material ID and selected properties
ABC101
Material ID ABC435 Nominal pH 6.3 Color Pale Yellow Density 1.42
DEF202 GHI303
Material ID XGH435 Nominal pH 7.0 Color Yellow Density 1.35
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Diagram Annotation
Diagrams may also be annotated May be used to include additional process, equipment, or other information of importance If a process annotation is used then the annotation shall be associated with an object or with the encapsulating process definition.
Process Note: If the mixture turns bright red, then the process temperature was to high and the material must be discarded.
Process Note: Make sure that process temperature is maintained between ring expansion and hydrolysis
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Process Operation Diagrams
Process Operation diagrams show Process Actions These are assumed to operate on the same material They need to show parallel and sequential actions Ø Similar structure to an SFC (IEC 61131-3 Sequential Function Chart) Ø Similar structure to a PFC (IEC 61512-2 Procedure Function Chart)
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Decide On A Process Action Model For Setting the Environment
There are at least two alternatives to setting the environment of the process Ø A non-persistent action model Ø A persistent action model Whichever model is chosen it is necessary to unambiguously communicate it to people who create master recipes from equipment independent recipes
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Environment Setting Process Action Model
One model has process actions that alter processing conditions Ø The environment within which further processing occurs Typically defined in terms of temperature, pressure, mixing state Process actions set the environment Ø Start mixing, stop mixing Ø Set pressure, ...
Charge Operation Heat On Mix ON add1 add2 Mix Off Heat Off Hold
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Nonpersistent Process Action Model
The non-persistent model defines process actions that define the environment only when they are active In this model a representation method is needed to document the parallel execution of process actions
Charge Operation
add wait add
heat
mix
Hold
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Sequential and Parallel Actions
Use the symbols below on a process operation diagram to construct complex sequential and parallel diagrams
Charge operation
Sequential Process Actions
add heat wait add mix hold wait add
Start of Parallel Process Actions
End of Parallel Process Actions
analyze
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Optional Parallel Actions
A special set of symbols are used when it is optional for actions to be executed either in parallel or in series It looks like a start and end of parallel, but using dashed lines, and an arrowhead on the parallel
Start of Optional Parallel Process Actions
End of Optional Parallel Process Actions
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Optional Parallel Actions
Usually used in mixing where it can occur in parallel, if the target equipment allows it, or can occur in series if it does not Usually related to measuring (weighing) materials
Charge op
Implemented in series
add5 add6
Charge op add1
add1 add2
add4
Implemented in parallel
Charge op
add2 add3
add3
add1 add2 inter add3
add4
add5
add6 add4 add5 add6
inter
inter
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Rules for Valid Diagrams
All of the elements in a PPC shall be connected. Ø Valid PPCs only have a single network of material flows. Valid PPCs shall start with one or more process inputs. Valid PPCs shall end with one or more process outputs. Valid PPCs shall have no loops of material dependencies.
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Table Representation
A graphical representation is not always needed Process operations are assumed to execute sequentially Many process operations only have sequential sets of process actions A simple table format may be easier to read and understand The table format also allows simple parallel definitions
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Table Representation
Assumed to execute from top to bottom The exact format is not defined, but it should show the action and any associated material(s) Sequence Order and Sequence Path can be used to show limited parallel and sequential actions
Sequence Order Sequence Path 0 0 0 0 0 Shot Add Temp Controlled Add Wait Rate Controlled Add Strip Top GHI303 XYZ909 Process Action ABC101 DEF202 Material
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Sequence Order and Sequence Path
Sequence path is used to indicate which sequential list the action is in (see figure below) Sequence order is used to indicate where in the parallel the action is (see figures next page)
Path 2
Charge op Charge op
Path 3
add wait add
heat
react add
mix hold
add wait add
heat
react add
mix hold
inter
inter
Path 1
Path 4
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Table representation Symbols
Action not under a tableau Cliquez sur l'icône pour ajouter unparallel Single action at start of a parallel (only action in path) Single action under a parallel (only action in path) Single action at end of parallel (only action in path) First in first series under a parallel (first action in first path) Action in middle of series under a parallel (not first or last in path) Last in last series of actions under a parallel (last action in last path) First in a series of actions under a parallel (first action in path) Last of series of actions under a parallel (last action in path)
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Displaying a Parallel in a Table
Hopefully, not frequently used for complex process operations But, useful for occasional complexity
Sequence Order Sequence Path 0 0 Process Action Charge Operation Add Wait ABC101 Material
Charge op
add
wait
0
add
0 0 Add Test DEF202
test
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PPC A Minimal Representation
Process Procedure Charts are a minimal representation Other views of the process definition may be needed by other users For example, a chemical view may be better for R&D chemists
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Summary
ISA 88 Part 3 defines a minimal standard representation Actually contains two types of diagrams Ø Material flows (showing stages and operations) Ø Sequence diagrams (showing operations and actions) A table format is also defined, usable for simple sequences and limited parallelism
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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ISA95 Operations Definition Model
The ISA-95 Operation definition model describe the purpose oriented activities of the industrial facilities Ø The "knowledge" about making the product, processing inventory operations, testing/qualifying resources and product, maintaining the facility equipment... Ø However, it does not expose the knowledge itself, but identifies its breakdown and resource commitment This model describes the product as a kind of achievement (here, the product) in terms of hierarchical stages, the "Operations segments" It shares the common segment pattern Ø See Physical Process Management
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ISA95 Operations Definition Model for Product
ISA95 focuses on supervising manufacturing, Ø It does not care much about processing details Ø It essentially manages resources The Operations Definition model implements a resource view of Product Asset Ø Can implement the product hierachy and EIR models Ø Based on the common Segment pattern It defines Ø Resource (Equipment, Personnel, Material) specification Ø Specific parameters Ø Links to external business information
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Operations Definition Model Elements (for Product)
Operations Definition (product) Ø "collection of information about materials, production rules and scheduling required to create a product" Operations Segment (product) Ø "logical grouping of resources (personnel, equipment, and material) specifications required of a process segment to complete a production step for a specific product Operations Material Bill (product) Ø "the subset of the bill of material that is related to production" Parameter Ø "Information that is required by the operation system for correct manufacturing" Resource (Personnel, Equipment, Physical Asset, Material) specification Ø "An identification, reference, or correspondence to a resource capability"
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Operations Definition Model
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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Operations Definition Model Elements (for Product)
Bill of materials Ø "listing of all the subassemblies, parts, and/or materials that are used in the production of a product including the quantity of each material required to make a product" Ø MRP II planning information Bill of resources Ø "listing of all resources and when in the production process they are needed to produce a product" Ø Production scheduling / Advanced planning and optimization information Work Definition Ø information used to instruct manufacturing operation how to produce a product - Refers to detailed Control system information, Manufacturing instructions (Recipes, Setup / assembly instructions...)
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Implementing the ISA Product Hierarchy model in ISA95
ISA 95 Operations Definition Operations Definition Operations Segment Operations Segment Operations Segment ISA 88 Product Hierarchy Process Procedure Process Stage Process Operation Process Action
Equipment specifications Material Specifications Parameters Equipment specification Material Specification Parameters Equipment specification Material Specification Parameters
Equipment Constraints Material In/Out Parameters Equipment Constraints Material In/Out Parameters Equipment Constraints Material In/Out Parameters
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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Practice
(1) Product Hierarchy Ø Give possible names and examples for the product hierarchy level (2) Product Parameter (3) Process Element Classes Ø For some process actions, define § Parameters (settings) § Data (Relevant information to collect) § Environment requirements § Pre-conditions § Post-conditions § Exception and handling (4) Process Definition Ø Define a Product procedure using the 4 standard levels § Up to the detail of an operation using some of the above Process Actions § Identify IN/OUT material from Exercises (1)
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Thank You !
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Work: ISA8895 Implementation Section: Structure Chapter: Knowledge Asset
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 ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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2
CC functional domains
ISA88 ISA95
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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
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Objective of the Knowledge Asset Modelling
The value of a product is set by the need of the market to own it Its manufacturing implies the combination of other products and their transformation The industrial solution to make the product is built on the specification of material combination and physico-chemical transformation required to obtain a congruent product Ø It basically defines the value creation stream of the product Ø Several « synthesis routes » can be defined Product Asset Modelling handles this specification that Ø Enables the product industrialization Ø Decouples the product value creation stream and the operating procedure (See « From Product to Process »)
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Objective of the Product Asset Modelling
Product Modelling provides an abstraction of the physical-chemical processing Ø It is independent of facilities physical layout and machinery capabilities Ø Variant of the same product definition may exist for different sites It highlights necessary material transformations to obtain the desired product Ø The Energy Chain primitive breakdown It is shared by all parties of the Money and Energy Chains Ø Provides a basic, consistent framework for benchmarking manufacturing segment between product, facilities and batches / production runs Ø Must correspond to a specific level of Product Segment: bi-directional Design (PLM) / Supply Chain integration
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Who's / What's concerned?
PRM Usr/Rsp Cliquez sur l'icône pour ajouter unUsage tableau 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
Material identification and equivalence
X
Determine quality criteria and protocoles
X
Production costing
R
Response to market, industrialize products
Build/adapt manufacturing facilities 2_40_ISA8895_Structure_ProductAsset
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Models Overview
This asset is described in a hierarchical manner 4 models address knowledge asset modelling Ø ISA88 Product Hierarchy Model § Called "Process model" in ISA88 Ø ISA95 Process Segment model Ø ISA95 Operations Definition model Ø ISA88 Equipment Independent Recipe Model § See « From Product to Process »
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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ISA88 Product Hierarchy Model
Addresses to the structural description of the company product knowledge asset Ø Hierarchical transformations to obtain a product Highly flexible, not constraining, Ø The hierarchy can be adapted: extended, collapsed, renamed Ø The "Batch taste" terminology can be adapted Ø Supports convergent / divergent processes Independent of the facility Ø No relationship with Physical Asset Ø Focuses on material transformation / combination Ø =/ equipment related operating procedure Ø Neutral basis for performance benchmarking
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ISA88 Product Hierarchy Model
Process Procedure
Process Elements
Process Stage
A sequence of chemical, physical, or biological activities for the conversion, transport, or storage of material or energy.
·
A part of a process that usually operates independently from other process stages and that usually results in a planned sequence of chemical or physical changes in the material being processed.
·
Process Operation
A major processing activity that usually results in a chemical or physical change in the material being processed and that is defined without consideration of the actual target equipment configuration.
·
Process Action
Minor processing activities that are combined to make up a process operation.
·
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Process Definition
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
The hierarchical sequence of process stages, process operations PROCESS and process actions that defines an ideal procedure for the ACTION manufacture of a successful product. Ø Specific rework processes can be defined as separate Process Procedures Inputs Ø Raw materials, purchased products Ø Intermediate products Ø Energy Outputs Ø Intermediate products Ø Co-product, by-products, Ø Energy
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Process Stage
PROCESS PROCEDURE PROCESS STAGE
A major transformation activity / a main product breakdown Ø a sequence of process operations = chemical or physical changes in the PROCESS ACTION material being processed Ø Independent: produces stable intermediate products Ø For the product production information / planning / supervision / process engineering Definition based on Ø Chemistry / Physics Ø Logistics Ø Engineering Inputs Ø Raw materials, purchased products Ø Intermediate products Ø Energy Outputs Ø Intermediate products: not necessarily identified from on PS to another Ø Co-product, by-products, Ø Energy 2_40_ISA8895_Structure_ProductAsset 13
PROCESS OPERATION
Process Stages definition rules
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Product physico-chemichal status Ø Chemical synthesis route Ø Main parts manufacturing and main assembly steps Major transformation Ø Obvious change in the nature or shape Combination / Separation Ø Based on convergence/Divergence points Intermediate Ø Independent / Asynchronous / Managed Ø Usable for several products Ø Can be sold as finished product Ø Can be sourced from external vendors
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Process Stages definition rules
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
Target facility PROCESS Ø Common equipment constraints for the process stage ACTION Ø Alignment on existing Work Center (Process Cell): The Process Stage corresponds to one or several Master Recipes Intermediate products planning Ø Within or separately of the finished product Ø Process Stage = Process Procedure for an intermediate Ø Planning of an intermediate: the Process Procedure contains the only corresponding Process Stage
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Process Operations
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
A major transformation activity PROCESS Ø A sequence of Process Actions ACTION Ø Operate in sequence on the material within the process stage Ø Irreversible chemical or physical change in the material being processed Ø Generally based on chemical or physical considerations Inputs Ø Raw materials, purchased products Ø Intermediate products Ø Energy Outputs Ø Intermediate products: not necessarily identified from on PS to another Ø Co-product, by-products, Ø Energy
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Process Operations definition rules
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
Natural organizational structure to identify major processing steps PROCESS Ø Obvious processing steps ACTION Ø Test and decision points Alignment to Master Recipes Ø Identification of possible operation boundaries for subsequently generated master recipes Equipment requirements identification for actions within the operation Supervision requirement Ø Long process breakdown Ø Finer granularity for manufacturing performance monitoring & benchmark
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Process Action
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
A basic processing activity, PROCESS Ø like grind, cool, heat, delay, test or mix ACTION Ø Addition or removal of material or energy, setting environment Process Actions within the operation Ø Operate on the defined materials in a defined sequence that may be serial / parallel / contain multiple branches Inputs / Outputs Ø Normally no product related I/O identified for Process Action § However, Process Actions act on Operation I/O Ø Processing Parameters and Processing Data
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Process Action Rules
Process Actions can be of different types. For example: Ø Material addition can be a fixed rate or controlled by a process variable such as a pressure, temperature, or pH Company specific process actions Ø unique company processing capabilities (separation, packaging...) Industry specific process actions, Ø such as catalytic conversions or property state changes.
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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ISA88 Equipment Independent Recipe Model
ISA88 defines 2 categories of recipes Ø EIR: Equipment Independent Recipes (General, Site) define how to manipulate materials to make a product Ø EDR: Equipment Dependent Recipes (Master, Control) specifies how to control equipment in order to make a product The Product Hierarchy based EIR Ø Describes the processing requirements § as a flow of material combinations and transformations Ø Identifies the produced and incorporated materials, parameters Ø Specifies the constraints applicable to the manufacturing equipment not the equipment itself Ø Supports the requirement specification to develop the operating procedure applicable to a particular facility § Complete, consistent, unambiguous § Understandable by R&D and engineering, at corporate and local levels
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ISA88 Equipment Independent Recipe Model
ISA88 Part 3 Extends the General/Site Recipe description in Part 1 Provide a standard way to maintain and exchange general recipes Ø Foreign plants, Contract manufacturing Developed collaboratively Ø Based on shared definition of processing capabilities, material master, equipment constraints Ø Within the enterprise and among its partners in manufacturing Ø Multiple different control system suppliers, integrators, and consultants
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ISA88 Equipment Independent Recipe model
EIR Recipe Process Product hierarchy "Process model" Process Stage Header Formula Equipment Constraints Other Information
From ISA-88 Part 3 Draft 13
Process Operation
Process Action
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Header
The administrative information in an equipment independent recipe is referred to as the header May include such items as Ø Recipe identification Ø Version number Ø Product identification Ø Product family Ø Product grade Ø Originator Ø Lifecycle state
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Formula
Includes Ø Process inputs Ø Process parameters Ø Process outputs Process inputs and process outputs identify Ø Materials and quantities of materials Ø Resources and quantities of resources § (Energy, ...)
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Formula: Material
Materials used in equipment independent recipes shall be identified by material definitions or material classes as defined in the ANSI/ISA 95.00.01 standard Ø Equipment independent recipes do not use material lot definitions Material definitions and material class definitions should be maintained in a material definition library to ensure that only valid material definitions are used in equipment independent recipes A material definition shall have an associated lifecycle state
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Formula: Relationship with the Inventory Asset Model
A material can correspond to an output of a particular Process element Ø A finished Product is the result of a Process Definition Ø An intermediate can be the result of a Process Stage or possibly of an operation Product Hierarchy level as Material Classes Ø Process Definition / Stage / Operation can be value for the class "ProductHierarchyLevel" = ProcessDefinition / ProcessStage / ProcessOperation Product Hierarchy level as Material Property Ø Process Definition / Stage / Operation can be value for the Property "ProductHierarchyLevel" = ProcessDefinition / ProcessStage / ProcessOperation
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Formula: Parameter
Correspond to ISA-95 Operations segment parameters
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Equipment Constraints
Equipment Constraints are a statement of the specific requirements of the final manufacturing equipment necessary to bring about the process activities May also document certain important attributes to select the suitable equipment needed in this process Used when the equipment properties may impact the chemistry or physics of production Used to define "hints" to manufacturing where R&D knows the properties of the material will cause problems if not carefully handled Equipment constraints correspond to ISA-95 Equipment specification properties in ISA-95 Operations segment model
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Example of Equipment Constraints
Constraint
ExternalHeatingCoils
Description
Specifies if any heating coils are external to the containing vessel, so they cannot be fouled by the batch material. Specifies if the containing vessel is glass lined and connecting pipes are Teflon lined. Specifies if the containing vessel and pipes are free of any elements containing nickel. Specifies if any transfers between vessels are short, so that unintended reactions (such as crystallize) will not occur in the piping. Specifies if any transfers between vessels are relatively straight, so that highly viscous or material prone to plugging may be transferred. Specified that the agitation method does not shear the batch material.
Constraint Type TRUE or FALSE TRUE or FALSE TRUE or FALSE TRUE or FALSE TRUE or FALSE TRUE or FALSE
LiningGlass
LiningNickelFree
TransfersShort
TransfersStraight
AgtitationNonSheared
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Other Information
A general recipe is a container of production information required for manufacturing, but it may also contain information for other business activities Examples of other information that might be included with equipment independent recipes are: Ø Spreadsheets detailing known process sensitivity models Ø Complete process models Ø Pictures of good products Ø Pictures of bad products and possible failure reasons Ø References to Test Methods & Test Specifications Ø References to material data safety sheets Ø Additional health and safety information Ø Packaging information
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Process Action Information
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Process Action is the most detailed Process Element Ø Its definition is critical for linking R&D to Process Engineering
§
Product Definition to manufacturing capabilities § Basis for optimizing the transformation of the product definition into executable operating procedure / Recipe
Information elements:
Ø Ø Ø Ø Ø Ø Ø Ø
Functionality resulting from its realization Parameters to modify its behavior Information resulting from its execution Environment conditions for its execution Pre-conditions for its correct execution Post-conditions resulting of its execution to be taken into account Known Exception conditions Handling of these exception conditions
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Classes Of Process Actions
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION
General actions deal with 1. Adding materials 2. Removing materials 3. Adding energy 4. Removing energy 5. Setting the environment (pressure, agitation...)
Company specific actions may PROCESS deal with unique ACTION 6. Material preparation 7. Material extraction 8. Material shaping 9. Material packaging 10. Material testing
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Examples Adding Material
Cliquez sur l'icône pour ajouter un tableau Process Action Functional Description Charge Parameters
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Add the specified material. There is no Material To Add rate constraint on the material addition. Amount to Add Usually used where there is no expected chemical reaction. Add the specified material at the specified rate and tolerance. Usually used when mixing is required or too fast a rate will cause an undesired chemical reaction.
ChargeAtRate
Material To Add Amount to Add Percent Per Minute % / Minute Tolerance Material To Add Amount to Add Maximum Temperature Minimum Temperature Temperature Tolerance
ChargeAtTemper Add the specified material so the ature temperature of the material being produced stays within the specified value. This can require heating or cooling capability. Usually used when an exothermic or endothermic chemical reaction will occur. 2_40_ISA8895_Structure_ProductAsset
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Examples Removing/Separating Materials
Process l'icône pour ajouter un tableau Cliquez sur Functional Description Action Dry Dry the material to remove any water or other safely evaporated materials. Parameters
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Material To Remove Expected Amount Removed Minimum Temperature Material To Remove Expected Amount Removed Evaporation Temperature Material To Remove Expected Amount Removed
Evaporate- Remove a solvent through evaporation. Solvent The solvent is to be retained and not dispersed into the atmosphere. FilterSolids Remove solids.
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Examples Adding Energy
Process Action pour ajouter un tableau Cliquez sur l'icône Functional Description Heat HeatProfile Induce energy to flow into the material. Parameters Final temperature
PROCESS PROCEDURE PROCESS STAGE PROCESS OPERATION PROCESS ACTION
Control the rate at which energy is Rate to heat added to the material. There can Holding temperature be one or many sets of Holding time parameters for different profiles.
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Equipment Independent Recipe Object Model
Why, Ø Because users wanted a standard way to maintain and exchange general recipes Ø To foreign plants Ø To contract manufacturing Ø To multiple different control system suppliers, integrators, and consultants The model Ø Does not define attributes § But it was enough to define a B2MML/BatchML XML exchange Ø Overlaps with ISA95 Product Definition Model § More dedicated, using ISA88 vocabulary
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EIR Object Model
Equipment Requirement Library
1..N
Is made up of
Is made up of
Process Element Library
1..N Is made up of
Equipment Independent Recipe
Has a type of
Material Definition Library
Is made up of 1..N
Equipment Requirement Element
1
Process Element Specification
1
General Recipe
1 1
Site Recipe
0..N
Material Definition
Corresponds 1 toÆ 0..N 0..N 1 Corresponds to Æ 0..N 0..N
May be derived from 0..N 0..N
Corresponds to Æ 0..N
Corresponds to Æ 0..N 0..N Has
Process Procedure
Is made up of 1..N
Other Information
0..N Has 0..N 1..N 1..N
Process Parameter
Process Input
0..N
Process Output
0..N
Equipment Requirement
0..N 0..N
Process Element
Has a type of
1
Process Element Link
Uses % of the input
1
Produces % of the output
Percent Input Process Action
Percent Output
Process Stage
1..N Is made up of
Process Operation
1..N Is made up of
From ISA-88 Part 3
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B2MML/BatchML implementation
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Handling General Recipe definition
Develop a standard corporate library of General Recipe elements Ø Material Definition Ø Equipment requirement definitions
These define what will be expected in final manufacturing equipment Each site can use this to determine how "capable" they are to meet R&D requirements § They describe to manufacturing sites exactly what equipment requirements will be asked for in production
§ §
Ø
Process actions definitions
Have manufacturing site determine its best manufacturing processes for each process action § These are used when creating master recipes § They describe to manufacturing sites exactly what processing they will be asked to perform to make products
§
They define a common language and provide a "contract" between manufacturing and R&D
Define all general and site recipes based on these standard definitions Ø Provide document management and change management of the definitions
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Summary
General and site recipes follow the same model as master recipes Ø Except they define a process not a procedure The standard includes guides to help identify the recipe elements (process stages, process operations, and process actions) Use of general and site recipes requires, as a minimum, libraries of process actions, materials, and equipment requirements Result will be faster and more reliable technology transfers
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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Equipment Independent Recipe Representation
Required within a company to standardize how they represent product definitions Ø Few companies have standard, formal, and unambiguous ways to describe pilot plant or R&D instructions to manufacturing ISA88 Part 3 defines the minimal representation method, Ø Graphical and table views defined Ø PFC for Process Function Chart
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General Recipe PPC (Process Procedure Chart)
7
Process Input representation (Material)
Nitration
2
Oxidation
13 8
22
Recipe annotation
Process Note: Make sure that process temperature is maintained between ring expansion and hydrolysis
Ring Expansion
55 1
12
Intermediate Material representation
Hydrolysis
10 2
Stage , operation, or action representation Process Output representation (Material)
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Graphical Recipe Representation
Use the material flow "PFC" notation within a Procedure Diagram Use SFC like notation within a Process Operation Diagram
Procedure Diagram Process Stage Diagram
M7
Process Operation Diagram
add wait
M7
M8
Premix
3
add
M8
Charge operation
Sterilize
2 8
add wait add
heat
wait add
mix hold
M9
Heat
9 2
M9
analyze
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Stage, Operation, and Action Graphical Representation
Rectangle represents a process stage, a process operation, or a process action The rectangle may be annotated
An identification Ø The number of underlying elements Ø The number of equipment requirements
Ø
Name
nn nn
Stage, Operation, or Action Name Stage, Operation, or Action Representation Indication on Underlying Elements Equipment Requirement Indication
12 04
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Material Representation
Materials are identified by arrows (directed lines) or arrows with circles
Process Input Representation Intermediate Material Representation
12
Any material may represent more than one material, with the addition of number inside the circle
Process Output Representation
Unidentified intermediate material
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Material Annotation
Materials may be annotated with the material ID May be annotated with material ID and selected properties
ABC101
Material ID ABC435 Nominal pH 6.3 Color Pale Yellow Density 1.42
DEF202 GHI303
Material ID XGH435 Nominal pH 7.0 Color Yellow Density 1.35
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Diagram Annotation
Diagrams may also be annotated May be used to include additional process, equipment, or other information of importance If a process annotation is used then the annotation shall be associated with an object or with the encapsulating process definition.
Process Note: If the mixture turns bright red, then the process temperature was to high and the material must be discarded.
Process Note: Make sure that process temperature is maintained between ring expansion and hydrolysis
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Process Operation Diagrams
Process Operation diagrams show Process Actions These are assumed to operate on the same material They need to show parallel and sequential actions Ø Similar structure to an SFC (IEC 61131-3 Sequential Function Chart) Ø Similar structure to a PFC (IEC 61512-2 Procedure Function Chart)
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Decide On A Process Action Model For Setting the Environment
There are at least two alternatives to setting the environment of the process Ø A non-persistent action model Ø A persistent action model Whichever model is chosen it is necessary to unambiguously communicate it to people who create master recipes from equipment independent recipes
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Environment Setting Process Action Model
One model has process actions that alter processing conditions Ø The environment within which further processing occurs Typically defined in terms of temperature, pressure, mixing state Process actions set the environment Ø Start mixing, stop mixing Ø Set pressure, ...
Charge Operation Heat On Mix ON add1 add2 Mix Off Heat Off Hold
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Nonpersistent Process Action Model
The non-persistent model defines process actions that define the environment only when they are active In this model a representation method is needed to document the parallel execution of process actions
Charge Operation
add wait add
heat
mix
Hold
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Sequential and Parallel Actions
Use the symbols below on a process operation diagram to construct complex sequential and parallel diagrams
Charge operation
Sequential Process Actions
add heat wait add mix hold wait add
Start of Parallel Process Actions
End of Parallel Process Actions
analyze
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Optional Parallel Actions
A special set of symbols are used when it is optional for actions to be executed either in parallel or in series It looks like a start and end of parallel, but using dashed lines, and an arrowhead on the parallel
Start of Optional Parallel Process Actions
End of Optional Parallel Process Actions
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Optional Parallel Actions
Usually used in mixing where it can occur in parallel, if the target equipment allows it, or can occur in series if it does not Usually related to measuring (weighing) materials
Charge op
Implemented in series
add5 add6
Charge op add1
add1 add2
add4
Implemented in parallel
Charge op
add2 add3
add3
add1 add2 inter add3
add4
add5
add6 add4 add5 add6
inter
inter
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Rules for Valid Diagrams
All of the elements in a PPC shall be connected. Ø Valid PPCs only have a single network of material flows. Valid PPCs shall start with one or more process inputs. Valid PPCs shall end with one or more process outputs. Valid PPCs shall have no loops of material dependencies.
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Table Representation
A graphical representation is not always needed Process operations are assumed to execute sequentially Many process operations only have sequential sets of process actions A simple table format may be easier to read and understand The table format also allows simple parallel definitions
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Table Representation
Assumed to execute from top to bottom The exact format is not defined, but it should show the action and any associated material(s) Sequence Order and Sequence Path can be used to show limited parallel and sequential actions
Sequence Order Sequence Path 0 0 0 0 0 Shot Add Temp Controlled Add Wait Rate Controlled Add Strip Top GHI303 XYZ909 Process Action ABC101 DEF202 Material
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Sequence Order and Sequence Path
Sequence path is used to indicate which sequential list the action is in (see figure below) Sequence order is used to indicate where in the parallel the action is (see figures next page)
Path 2
Charge op Charge op
Path 3
add wait add
heat
react add
mix hold
add wait add
heat
react add
mix hold
inter
inter
Path 1
Path 4
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Table representation Symbols
Action not under a tableau Cliquez sur l'icône pour ajouter unparallel Single action at start of a parallel (only action in path) Single action under a parallel (only action in path) Single action at end of parallel (only action in path) First in first series under a parallel (first action in first path) Action in middle of series under a parallel (not first or last in path) Last in last series of actions under a parallel (last action in last path) First in a series of actions under a parallel (first action in path) Last of series of actions under a parallel (last action in path)
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Displaying a Parallel in a Table
Hopefully, not frequently used for complex process operations But, useful for occasional complexity
Sequence Order Sequence Path 0 0 Process Action Charge Operation Add Wait ABC101 Material
Charge op
add
wait
0
add
0 0 Add Test DEF202
test
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PPC A Minimal Representation
Process Procedure Charts are a minimal representation Other views of the process definition may be needed by other users For example, a chemical view may be better for R&D chemists
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Summary
ISA 88 Part 3 defines a minimal standard representation Actually contains two types of diagrams Ø Material flows (showing stages and operations) Ø Sequence diagrams (showing operations and actions) A table format is also defined, usable for simple sequences and limited parallelism
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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ISA95 Operations Definition Model
The ISA-95 Operation definition model describe the purpose oriented activities of the industrial facilities Ø The "knowledge" about making the product, processing inventory operations, testing/qualifying resources and product, maintaining the facility equipment... Ø However, it does not expose the knowledge itself, but identifies its breakdown and resource commitment This model describes the product as a kind of achievement (here, the product) in terms of hierarchical stages, the "Operations segments" It shares the common segment pattern Ø See Physical Process Management
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ISA95 Operations Definition Model for Product
ISA95 focuses on supervising manufacturing, Ø It does not care much about processing details Ø It essentially manages resources The Operations Definition model implements a resource view of Product Asset Ø Can implement the product hierachy and EIR models Ø Based on the common Segment pattern It defines Ø Resource (Equipment, Personnel, Material) specification Ø Specific parameters Ø Links to external business information
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Operations Definition Model Elements (for Product)
Operations Definition (product) Ø "collection of information about materials, production rules and scheduling required to create a product" Operations Segment (product) Ø "logical grouping of resources (personnel, equipment, and material) specifications required of a process segment to complete a production step for a specific product Operations Material Bill (product) Ø "the subset of the bill of material that is related to production" Parameter Ø "Information that is required by the operation system for correct manufacturing" Resource (Personnel, Equipment, Physical Asset, Material) specification Ø "An identification, reference, or correspondence to a resource capability"
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Operations Definition Model
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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Operations Definition Model Elements (for Product)
Bill of materials Ø "listing of all the subassemblies, parts, and/or materials that are used in the production of a product including the quantity of each material required to make a product" Ø MRP II planning information Bill of resources Ø "listing of all resources and when in the production process they are needed to produce a product" Ø Production scheduling / Advanced planning and optimization information Work Definition Ø information used to instruct manufacturing operation how to produce a product - Refers to detailed Control system information, Manufacturing instructions (Recipes, Setup / assembly instructions...)
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Implementing the ISA Product Hierarchy model in ISA95
ISA 95 Operations Definition Operations Definition Operations Segment Operations Segment Operations Segment ISA 88 Product Hierarchy Process Procedure Process Stage Process Operation Process Action
Equipment specifications Material Specifications Parameters Equipment specification Material Specification Parameters Equipment specification Material Specification Parameters
Equipment Constraints Material In/Out Parameters Equipment Constraints Material In/Out Parameters Equipment Constraints Material In/Out Parameters
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Agenda
Introduction ISA88 Product Hierarchy Model ISA88 Equipment Independent Recipe Model ISA88 PPC representation ISA95 Operations Model Practice
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Practice
(1) Product Hierarchy Ø Give possible names and examples for the product hierarchy level (2) Product Parameter (3) Process Element Classes Ø For some process actions, define § Parameters (settings) § Data (Relevant information to collect) § Environment requirements § Pre-conditions § Post-conditions § Exception and handling (4) Process Definition Ø Define a Product procedure using the 4 standard levels § Up to the detail of an operation using some of the above Process Actions § Identify IN/OUT material from Exercises (1)
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Thank You !
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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)