.
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
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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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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
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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
§
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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
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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
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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
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(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
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(1) Decisional focus : Hierarchy according to ISA95
ENTERPRISE
SITE
AREA
Work Center
Work Unit
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(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
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(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
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(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)
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(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
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(3) Timing focus : Main activity flows
Detailed Scheduling Resource Management
Tracking Analysis Data Collection
Dispatching Definition Management Execution Management
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(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
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Agenda
Introduction ISA95 Operation Activity Model (Production example) Operation Processes / Task definition
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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Applying the Activity model to other MOCs
Inventory Quality Control Maintenance +...
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Supporting functions
These functions provide Ø Suitable technical framework Ø Global services and procedures Ø Not directly linked to Production's main purpose
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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
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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
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Agenda
Introduction ISA95 Operation Activity Model (Production example) Operation Processes / Task definition
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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),
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Iterative OP/Task Definition
OP Identification OP Design/Task Id Task Description
Operation Processes
Tasks Task Classification
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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
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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
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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
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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
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Business Process Design : BPMN Language
BP Identification BP Design/Task Id Task Description Task Classification
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Business Process Design : BPMN Language
BP Identification BP Design/Task Id Task Description Task Classification
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Business Process Design : BPMN Language
BP Identification BP Design/Task Id Task Description Task Classification
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Example
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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
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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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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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
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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
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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
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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
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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
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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
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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
§
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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
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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
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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
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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
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(1) Decisional focus : Hierarchy according to ISA95
ENTERPRISE
SITE
AREA
Work Center
Work Unit
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(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
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(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
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(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)
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(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
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(3) Timing focus : Main activity flows
Detailed Scheduling Resource Management
Tracking Analysis Data Collection
Dispatching Definition Management Execution Management
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(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
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Agenda
Introduction ISA95 Operation Activity Model (Production example) Operation Processes / Task definition
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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Applying the Activity model to other MOCs
Inventory Quality Control Maintenance +...
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Supporting functions
These functions provide Ø Suitable technical framework Ø Global services and procedures Ø Not directly linked to Production's main purpose
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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
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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
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Agenda
Introduction ISA95 Operation Activity Model (Production example) Operation Processes / Task definition
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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),
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Iterative OP/Task Definition
OP Identification OP Design/Task Id Task Description
Operation Processes
Tasks Task Classification
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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
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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
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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
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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
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Business Process Design : BPMN Language
BP Identification BP Design/Task Id Task Description Task Classification
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Business Process Design : BPMN Language
BP Identification BP Design/Task Id Task Description Task Classification
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Business Process Design : BPMN Language
BP Identification BP Design/Task Id Task Description Task Classification
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Example
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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
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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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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(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
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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
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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
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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
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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
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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
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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)