“How Process Industries Stand -...
Transcript of “How Process Industries Stand -...
1© ARC Advisory Group
“How Process Industries Stand to benefit from seeking ISA 95
frameworks incorporated in Your RFPs”
Eighth ARC India Forum, Hyderabad July 2010
“Achieving Business Excellence through IT and Automation Solutions”
Satya SahuMESA India Member
Photograph of Speaker
Kamal AjitsariaMESA India Member
2© ARC Advisory Group
Agenda
Evolution and Introduction to ANSI/ISA-95 (S95) Standard
Benefits by incorporating S95 standards in RFPs
3© ARC Advisory Group
Agenda
Evolution and Introduction to ANSI/ISA-95 (S95) Standard
Maintenancedata
collection
Maintenenceexecution
Maintenenceresource
management
Maintenancedispatching
Maintenancetracking
Maintenanceresponse
Detailedmaintenancescheduling
Maintenancerequest
Maintenencedefinition
management
Level 1-2 Equipment
MaintenancePerformance
analysis
Maintenancecapability
Maintenancedefinition
Inventorydata
collection
Inventoryexecution
Inventoryresource
management
Inventorydispatching
Inventorytracking
Inventoryresponse
Detailedinventory
scheduling
Inventoryrequest
Inventorydefinition
management
Level 2 Equipment
inventoryPerformance
analysis
Inventorycapability
Inventorydefinition
Productiondata
collection
Productionexecution
Productionresource
management
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Productdefinition
management
Level 2 Process Control
ProductionPerformance
analysis
Productioncapability
Productdefinition
Quality testdata
collection
Quality testexecution
Quality testresource
management
Quality testdispatching
Quality testtracking
Quality testresponse
DetailedQuality testscheduling
Quality testrequest
Qualitydefinition
management
Level 1-2 Equipment
QualityPerformance
analysis
Quality testcapability
Quality testdefinition
4© ARC Advisory Group
Special Thanks to
Arne Svendsen, Director, Arla Foods, Manufacturing Services & Automation
Dave Emerson, Member of ISA-95 and Author of B2MML
Charlie Gifford, Chief Manufacturing Consultant, 21st Century Manufacturing Solutions
5© ARC Advisory Group
Topics
What is the current situation?
ISA-95 Overview
B2MML Overview
Best Practices of B2MML Extension
Customer Success Story
6© ARC Advisory Group
Agenda
What is the Current Situation?
7© ARC Advisory Group
Manufacturing System Separation
What’s happening during every shift? Material availability and consumption Capacity availability and utilization Schedule changes Product genealogy tracking and QM
What’s happening at each line? Cycle times and operating efficiencies Machine breakdowns and unplanned
downtime Quality index Predictive maintenance requirements
How are we hitting our targets? Total cost of production and variance Labor and resource productivity Order fill rates and cycle times Fixed and variable asset utilization
ERP
MOM: Manufacturing Operation Management
SFAC – Shop floor automation and control systems
DCS – Distributed control systems
MOM
SFAC
?
?
?
DISCONNECT
DISCONNECT
DISCONNECT
DISCONNECT
8© ARC Advisory Group
What is the reality of B2M Synchronization?A Manufacturing Execution Perspective
The ERP system is the leading system for
production planning,
initiating the manufacturing execution and
cost control via production orders
MES System execute the manufacturing processes
Current practices to Integrate ERP with MES
Homegrown “Non-Standardized” Interfaces
Cost Intensive to development and Maintain
No Visibility for monitoring Control
9© ARC Advisory Group
Supporting Standards
Moving to Interoperability
Supplier
App
App
App
App
ERPC
usto
m
In
teg
rati
on
Non-Standard
ERP
Supplier
App
App
Interoperability
10© ARC Advisory Group
What ISA-95 Offers
Framework for integration projects
Where business processes is separated from manufacturing processes
Focus on functions, not systems, organizations or individuals
11© ARC Advisory Group
Some End Users of the ISA-95 Standard
Energy• ExxonMobil, Inc
• Kuwait National Petroleum Company
• ExxonMobil Neftegas Limited
• BP
• British Gas
• Caspian Pipeline Consortium
• U.S. Department of Energy
• GasOil Resources LLC
• Sakhalin Energy
• Westinghouse Savannah River
Discrete Manufacturing• Advanced Micro Devices
• JDS Uniphase
• Computer Sciences Corporation
• GE Lighting
• GE Aircraft Engines
• Lucent
• Alcatel
• Cummins
Other• International Paper
Life Sciences• Eli Lilly and Co.
• Merck
• Genentech
• Roche Diagnostics
• TEVA
Food and Beverage• Nestle
• Coca-Cola North America
• Arla Foods
• United Biscuits Verkade Zaandam
• Van Dijk Food Products Zeewolde
• Cerveceria Polar
• GumLink
• SAB Miller
• Frito-Lay
• Red Gold Tomatoes
Consumer Goods• P&G
• British American Tobacco
Chemical• DOW Chemical
• Dupont
• SABIC (Saudi Arabia)
• Polaroid
12© ARC Advisory Group
ISA-95 a Manufacturing Standard
Original work focused on production of manufacturing plants
Expanded to
• Maintenance
• Inventory
• Quality Data
Defines models andterminology
Independent of data exchangetechnology
13© ARC Advisory Group
Functions in Domains
Procurement
(5.0)
Production
Scheduling(2.0)
Material and
Energy Control(4.0)
Product
Inventory Control(7.0)
Product Cost
Accounting(8.0)
Quality
Assurance(6.0)
Research
Developmentand Engineering
Product
Shipping Admin(9.0)
Order
Processing(1.0)
Marketing
& Sales
Production
Control(3.0)
Maintenance
Management(10.0)
Pack Out Schedule
Finished Goods Inventory
Finished G
oods W
aiverProcess Data
Short Term Material
and Energy Requirements
Material and Energy
Inventory
Production Capability
Production From Plan
Schedule
Incoming material and
energy receipt
Pro
duct
ion
Cos
t
Obj
ective
s
Pro
duct
ion
Per
form
ance
and
cost
Con
firm
to s
hip
Rele
ase t
o s
hip
QA
Results
Pro
duct
and
Pro
cess
Req
uire
ments
Standards and
Customer
Requirements
Standards and Customer
Requirements
In Process Waiver
Request
Process Data
QA Results
Pro
duct a
nd P
rocess K
now
How
Pro
duct a
nd P
rocess T
echnic
al F
eedback
Main
tena
nce S
tanda
rds
and
Meth
ods
Main
tena
nce T
echnic
al
Feedb
ack
Maintenance
Purchase Order
Requirements
Mate
rial a
nd
Energ
y O
rde
r
Req
uire
ments
Incom
ing
Ord
er
Con
firmatio
n
Long T
erm
M
ate
rial and
energ
yre
quirem
ents
Production O
rders
Availa
bility
Pro
duct a
nd P
rocess In
form
atio
n R
equest
Main
tena
nce R
equests
Main
tena
nce R
esp
onses
Enterprise/
Control
Boundary
14© ARC Advisory Group
System Separation & the Industry Standards
Level 4
Level 1
Level 2
Level 3
Business Planning
& LogisticsPlant Production Scheduling,Operational Management, etc
Manufacturing
Operations ManagementDispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Batch
Control
Discrete
ControlContinuous
Control
Manufacturing Operations
(MES, LIMS, QM, AM,…)
Business Logistics
Systems (ERP)
Automation Systems
(DCS, PLC, OCS, …)
Interface defined
in ISA95.01 and ISA95.02 &
B2MML
Area addressed
ISA-95 Parts 3 & 4
15© ARC Advisory Group
ResourceInformation
(Personnel, Equipment,
Material,Segments)
Exchanged Level 3-4 Information
Manufacturing operations &control information
Production operations, maintenance
operations, quality operations, etc
Business planning &logistics informationPlant production scheduling,operational management, etc
Productdefinition
information(What must bedefined to make
a product)
Productioncapability
information(What resources
are available)
Productionschedule
information(What to
make and use)
Productionresponse
information(What was
made and used)
16© ARC Advisory Group
Production Schedule
People
Materials
Equipment
Segments Product
Definitions
Production
Schedule
17© ARC Advisory Group
How it’s mapped to actual data exchange?
ISA-95 Models Direction Scenario
Production Schedule ERP -> MES - Process Order Download
- Production Order Download
- Control Receipe Download
- Planned Order Download
Production
Performance
MES -> ERP - Process Order Confirmation
- Production Order Confirmation
- Repetitive Manufacturing Confirmation
Product Definition ERP -> MES - BOM Download
- Routing Download
Maintenance ERP -> MES - Maintenance Order Download
MES -> ERP - Maintenance Order Create
- Maintenance Notification Create
Material ERP -> MES - Batch Download
MES -> ERP - Batch Create
- Batch Change
Equipment ERP -> MES - Workcenter Download
18© ARC Advisory Group
ISA-95 Part 3
Manufacturing Operations Management
19© ARC Advisory Group
ISA-95 Part 3 – Defines Level 3 Activities
Batch
Control
Continuous
Control
Discrete
Control
Business Planning
& Logistics
Manufacturing
Operations Management
Batch
Control
Continuous
Control
Discrete
Control
Business Planning
& Logistics
Manufacturing
Operations Management
Datacollection
Executionmanagement
Resourcemanagement
Dispatching
Tracking
Operationsresponse
Detailedscheduling
Operationsrequest
Definitionmanagement
Analysis
Operationscapability
Operationsdefinition
parameters andprocedures
Processspecific data
responsescommands
Datacollection
Executionmanagement
Resourcemanagement
Dispatching
Tracking
Operationsresponse
Detailedscheduling
Operationsrequest
Definitionmanagement
Analysis
Operationscapability
Operationsdefinition
parameters andprocedures
Processspecific data
responsescommands
Production
Maintenance
Inventory
Quality
Materials
Purchasing
Product
Development
Operations
Planning
Asset
Management
Order
Management
Distribution
& Logistics
Information PipelineCustomer
Service
Raw
Material
Storage &
Transport
Unit
Processing
Intermediate
Storage
Storage &
Transport
Unit
Processing
Product PipelineDistribution
MOM = Manufacturing Operations Management
20© ARC Advisory Group
Datacollection
Executionmanagement
Resourcemanagement
Dispatching
Tracking
Operationsresponse
Detailedscheduling
Operationsrequest
Definitionmanagement
Analysis
Operationscapability
Operationsdefinitions
ISA-95 Part 3 Generic Model
Apply to:
Production
Maintenance
Inventory
Quality Data
21© ARC Advisory Group
ISA-95 Part 3 Operation Models
InventoryDefinition
Inventory OperationsQuality Operations
Testcommands
Testresponses
Quality TestData
CollectionQuality TestExecution
Management
Quality TestResource
Management
Quality TestDispatching
Quality TestTracking
Quality testPerformance
DetailedQuality TestScheduling
Quality testSchedule
Quality TestDefinition
Management
Quality Test Level 1-2 Functions
Quality TestPerformance
Analysis
Quality testCapability
Quality testDefinition
Qualityparameters and
procedures
Qualityspecific data
MaintenanceDefinition
Maintenancecommands and
procedures
Maintenanceresults
MaintenanceData
CollectionMaintenanceExecution
Management
MaintenanceResource
ManagementMaintenanceDispatching
MaintenanceTracking
MaintenancePerformance
DetailedMaintenanceScheduling
MaintenanceSchedule
MaintenanceDefinition
Management
Maintenance Level 1-2 Functions
MaintenancePerformance
Analysis
MaintenanceCapability
Equipment specific maintenance procedures
Equipmentstate of
health data
Maintenance Operations
Inventorycommands
Inventoryreplies
InventoryData
CollectionInventoryExecution
Management
InventoryResource
Management
InventoryDispatching
InventoryTracking
InventoryPerformance
DetailedInventoryScheduling
InventorySchedule
InventoryDefinition
Management
Inventory Level 1-2 Functions
InventoryPerformance
Analysis
InventoryCapability
Inventorystorage definitions
Inventoryspecific data
ProductionPerformance
ProductionSchedule
ProductionCapability
ProductDefinition
Operationalcommands
Operationalresponses
ProductionData
CollectionProductionExecution
Management
ProductionResource
Management
ProductionDispatching
ProductionTracking
DetailedProductionScheduling
ProductDefinition
Management
Production Level 1-2 Functions
ProductionPerformance
Analysis
Equipment and processspecific production rules
Equipment andprocess specific data
Production Operations
22© ARC Advisory Group
B2MMLBusiness To Manufacturing Markup
Language
23© ARC Advisory Group
What Is B2MML?
B2MML = Business To Manufacturing Markup Language
Standards based, vendor independent XML schema implementation of ISA-95
• B2MML follows the functional lead of the ISA-95 standard
• Emerging as the preferred integration method, Especially for companies integrating MES to SAP systems
Tool for bringing together automation& IT groups
• Information familiar to automationprofessionals in an IT acceptable format
Logical progression when ISA-95standard used for analysis and design
Developed by and available from the WBF
• www.wbf.org
ISA-95/B2MML
24© ARC Advisory Group
B2MML XML Schemas
Common Schema
Confirm BOD
SchemaExtensions Schema
Transaction Profile
Schema
Core Components
Schema
Production Schedule
Schema Material Schema
Production Response
SchemaEquipment Schema
Product Definition
SchemaMaintenance Schema
Production Capability
Schema
Process Segment
SchemaPersonnel Schema
26© ARC Advisory Group
Best Practices of B2MML Schema Extension
27© ARC Advisory Group
Why it’s required?
ISA-95 Provides a framework for Shopfloor-Topfloor Integration projects
• Hence, not all data elements are part of interface structure
B2MML Provides “Flexible extension” mechanism for extension
28© ARC Advisory Group
Extension Methods
Properties
• Define properties in ID-Value combination, where available to avoid requiring schema extensions
“Any” Field
Extension Method
• New extension method introduced in v0300
• Allows for XML validation of extended schemas
• Recommended method for extensions
29© ARC Advisory Group
Properties
Intention of ISA-95 committee is to use property values to handle data not supported as object attributes in the standard
This should be used in as many cases as possible
• Using properties can avoid requiring extensions in some cases
Only some objects have properties• B2MML provides properties per ISA-95• Limits use of this option
30© ARC Advisory Group
Extension Method - Import, Include, and NameSpace
B2MML CommonSchema
B2MML Production
Schedule Schema
B2MMLXML
Document
Include
Namespace Reference
B2MML Extensions
Schema
Import
Namespace Reference
Does not disturb the original Schema Structure
31© ARC Advisory Group
Arla Food’s Success Story
32© ARC Advisory Group3
2
Arla Foods: Figures & Products
Arla is one of Europe’s Leading Dairy Suppliers
65+ Production Sites across the world
7 Billion Euro annual, 17.000 employees
Cooperative business owned by DK/SE farmers
Largest producer of organic products
33© ARC Advisory Group3
3
Business- and Manufacturing-IT history & key figures
Business-IT:
• 2001 – 2006: One Arla SAP roll-out.
• 2006: Outsourcing contract of all, except overall coordination –and Manufacturing-IT !
• 2008: Upgrading til SAP 6.0.
• Governance: ”ITIL”
• One Service contract
Manufacturing-IT:
•2002-03: Selling ”Production-IT” into the Arla business
•2004: Choosing MES vendor
•2004: 1st B2MML go-live.
•2009: Team of 35 supporting 30+ sites in Arla DK, SE. Production 40.000 man hours.
•Budget < 5% of Global IT !
•Governance: Agile model
•Sourcing: Local- language integrators used per country.
34© ARC Advisory Group
Manufacturing IT answer to business requirements:
The “history”: Arla evolved from mergers & acquisitions and therefore has a highly heterogeneous manufacturing environment on the plant floor.
To solve the challenge of incoming Business requirements and the “history”, an Integrated Manufacturing Strategy has been decided:
A SAP template, including all Logistics modules (QM, PP-PI ..) is under roll-out.
A Global standard MES platform is under roll-out.
A strategy to integrate ERP-data with plant-floor data has been developed.
35© ARC Advisory Group3
5
B2MML because .. of IT cost cutting
Arne Svendsen Copyright © 2004 World Batch Forum Slide 7
Scenario 1: Suppliers proprietary
solutions
B2MML because..
PI-PCS ……
SAP Business Connector / XML
MESSystem X
Plant A,B,C ..
MESSystem Y
Plant M,N,..
MESSystem ..
Plant ..
S95/WBF standard
(B2MML XML)
PLC PCS
Scenario 2: Open standard
SAP R/3
MM – PP-PI – QM
PLCPLC PLC
SAP R/3
MM – PP-PI – QM
MES/PCSPlant X
MES/PCSPlant Y
MES/PCSPlant ..
PI-PCS ……
36© ARC Advisory Group36
Typical
Legacy
system
M = Manual interface
SAPfunctionality
Production Operations: ”Legacy apps”
Equipment and processspecific production rules
Equipment and processspecific data
Productiondata
collection
Productionexecution
management
Productionresource
management
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Productdefinition
management
Production level 1-2 functions
Productionanalysis
Productioncapability
Productdefinition
Operationalresponses
Operationalcommands
Detailedproductionscheduling
M M
MM M
M
37© ARC Advisory Group37
Arla
Global MES
Solution
M = Manual interface
SI = Standard interface
Production Operations: Large-site solution
Equipment and processspecific production rules
Equipment and processspecific data
Productiondata
collection
Productionexecution
management
Productionresource
management
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Productdefinition
management
Production level 1-2 functions
Productionanalysis
Productioncapability
Productdefinition
Operationalresponses
Operationalcommands
Detailedproductionscheduling
SI
SISI
SI
SISISI
SISI
38© ARC Advisory Group
The Integrated Manufacturing solution map..
Order dispatching
PROCESS PACKAGINGRaw Matl. Fin. Goods
Process Control / Machine Control
Scan
RFID
APO SAP
PP-PI QM PMNetWeaver / XI
Product Definition,
Formula Management
APO SAP
PP-PI QM PMNetWeaver / XI
Downtime,
OEE
Traceability
Matl. Tracking. Maintenance data acq
Energy & Envir. data
Enterprise integrationS95/ B2MML
PROCESS PACKAGINGRaw Matl. Fin. Goods
Process Control / Machine Control
Scan
RFID
Rich HMIProduction Execution
Equipment ModelEquipment Model
Plant
Database
Product Quality
(QA / QC / SPC)
Process Analysis,
PAT
Arla
Intranet
(EP)
xMII Central Instance
Plant Reports
xMII
xMII
xMII
Site
server
SAP xMII for S95 B2M integration
39© ARC Advisory Group3
9
The costs ?
2003-2006 2007 2008
Specification
R/3 -config
MES-config
Testing +go-live
24x7
XI-config
24x7
Specification
R/3 -config
MES-config
Testing +go-live
24x7
xMII-config
24x7R/3 -config
MES-config
Testing +go-live
24x7
xMII-config
24x7
Specification
40© ARC Advisory Group
Agenda
Benefits by incorporating S95 standards in RFPs
41© ARC Advisory Group
Incorporating S95 Standards in RFP
Functional Scope of L3 MOM vis-à-vis out of scope in L4 and L1 & L2
Procurement
(5.0)
Production
Scheduling(2.0)
Material and
Energy Control(4.0)
Product
Inventory Control(7.0)
Product Cost
Accounting(8.0)
Quality
Assurance(6.0)
Research
Developmentand Engineering
Product
Shipping Admin(9.0)
Order
Processing(1.0)
Marketing
& Sales
Production
Control(3.0)
Maintenance
Management(10.0)
Pack Out Schedule
Finished Goods Inventory
Finished G
oods W
aiverProcess Data
Short Term Material
and Energy Requirements
Material and Energy
Inventory
Production Capability
Production From Plan
Schedule
Incoming material and
energy receipt
Pro
duct
ion
Cos
t
Obj
ective
s
Pro
duct
ion
Per
form
ance
and
cost
Con
firm
to s
hip
Rele
ase t
o s
hip
QA
Results
Pro
duct
and
Pro
cess
Req
uire
ments
Standards and
Customer
Requirements
Standards and Customer
Requirements
In Process Waiver
Request
Process Data
QA Results
Pro
duct a
nd P
rocess K
now
How
Pro
duct a
nd P
rocess T
echnic
al F
eedback
Main
tena
nce S
tanda
rds
and
Meth
ods
Main
tena
nce T
echnic
al
Feedb
ack
Maintenance
Purchase Order
Requirements
Mate
rial a
nd
Energ
y O
rder
Require
ments
Incom
ing
Ord
er
Confirm
atio
n
Long T
erm
M
ate
rial and
energ
yre
quirem
ents
Production O
rders
Availa
bility
Pro
duct a
nd P
rocess In
form
atio
n R
equest
Main
tena
nce R
equests
Main
tena
nce R
esp
onses
Business case based on criticality for
• Plant Efficiency• Quality• Reliability• Compliance
• ISA-95 Part 3 diagrams is spot-on to visualize solution road maps for production management
• Eye-opener to see similar patterns across production, maintenance, quality & inventory. Help selling IT road maps in to the business
L3 MOM functionalities using S95 Part 3 Activity Models
Arla Foods experience
42© ARC Advisory Group
Incorporating S95 Standards in RFP
Integration Scope: What needs to be exchanged between L3 MOM and L4 systems such as PLM and ERP
Architectural considerations such as B2MML
• What was made
• How much was made
• What was used
• What were the wastes
• What to make
• When to make
• How to make
• What to use
PP MM QM PM
• Production Schedule
• BOR
• BOO
• Production
Confirmation
• Key Metrics
• Resource utilizations
• M-BOM
• Store RM Inventory
• WIP Inventory
• Floor FG Inventory
• Store FG Inventory
• Quality Specs
Definitions
• Inspection Schedules
• Inspection Data
• QI Notif ications
• Deviations and CAPA
• Work center
Availability
• Maintenance
Schedules
• Maintenance Orders
and Requests
• Energy and MRO
Consumptions
Production Scheduling
Inventory Management
Quality Management
Maintenance Management
• Open standards based, vendor
independent XML schemas based
on ISA-95
• Enables integration project teams
to use ISA-95 during analysis &
design then use XML during
implementation
43© ARC Advisory Group
Top5 Reasons for Incorporating S95 in RFP
Accurate & Comprehensive articulation of functional scope
Ensure selected products are S95 compliant
Reducing buffering in service quote due to scope uncertainty
Better comparison of solution and costs from various vendors
Hit the ground running towards building a scalable and interoperable system
44© ARC Advisory Group
Agenda
Thanks!!!