Jean Vieille 2010
Attribution-NonCommercial-ShareAlike Creative Commons 3.0 Unported .
Paternité - Pas d'Utilisation Commerciale - Partage des Conditions Initiales à l'Identique
Work: ISA8895 Implementation
Section: Overview
Chapter: Modelling
Language: English
Version: V2 - 10/2010
www.controlchainmanagement.net
[email protected]
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
1
Agenda
■
■
■
■
■
■
■
ISA-88 snapshot
ISA-95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
2
Automation challenge
Ideal Automation
Flexibility
ISA-88
« manual
Control »
Capability
Darin Flemming
Lou Pillai
« Classical » Automation
Intelligent
Industrial
Systems
Complexity
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
3
ISA-88 standard
■ US and International “Batch Control” standard
■ The ISA88 committee develops the US ANSI standard
■ The IEC65A WG11 develops the IEC international standard
US standard
INTL Standard
Sub Title
ANSI/ISA-88.00.01:
2010
IEC 61512-1:
1997
Part 1: Models and Terminology”
ANSI/ISA-88.00.02:
2001
IEC 61512-2:
2001
Part 2: Data structures and guidelines for
languages
ANSI/ISA-88.00.03:
2003
IEC 61512-3:
2008
Part 3: General and Site Recipe - Models and
Representation
ANSI/ISA-88.00.04:
2006
IEC 61512-4:
2009
Part 4: Batch Production Records
ISA Draft88.00.05
-
Part 5: Implementation Models & Terminology for
Modular Equipment Control
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
4
ISA-88 snapshot
■ Object Design of automation applications
 Reuse, Knowledge Management, Robustness
■ Flexible Design of automation applications - No programming required for
 Modification of recipes, making different products with the same facility
 Using alternate equipment for the same production step
 Sequencing production runs for different products
■ Interoperability
 Assembling software components from different origins
■ Product Industrialization
 Neutral specification of product physico-chemical transformations
 Conversion of this specification into operating procedure for target facilities
■ Production Information
 Data structures for production information history
 Includes several ISA-95 models
■ Applications
 Initially designed for Batch processes, but applicable to any type of process
 Functional specification, batch managers, historians, PDM/PLM
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
5
ISA-88 Adoption
■ Automation Functional Engineering Good Practices
 Largely applied worldwide, proven benefits
■ Best known in process industries
 Less in other domains…
■ All automation vendors offer solutions
 Generally limited to the support of recipes (authoring, execution, reporting)
 Sometime at the equipment control level
■ Applies more and more to all types of production
 No equivalent standards for discrete and continuous processes…
 Adapt easily
 Most benefits with globalized application: all types of processes, all locations
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
6
Agenda
■
■
■
■
■
■
■
ISA-88 snapshot
ISA-95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
7
ISA-95 snapshot
■ B2M: Collaboration Business / Execution
 Communication between execution systems (MES/MOM, DCS, MMS,
LIMS, WES, SCADA,…) and business systems (ERP, SCM)
 Master data management
■ MES/MOM : Functional definition
■ Data and Activity models
 Description of resources, capability, products, work order requests
and reports
 Definition of operation management activities (MES)
■ Applications:
 User requirements and functional specification of MES and B2M
interfaces
 Native B2M connectors - MES/ERP (B2MML)
 Possible basis for developing MES applications and software…
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
8
What is ISA-95?
■ US & International standard “Enterprise - Control System Integration”
■ The ISA95 committee develops the ISA-95 standards
■ The ISO/IEC JWG5 develops the international standard
US standard
INTL Standard
Sub Title
ANSI/ISA-95.00.01:
2010
IEC/ISO 62264-1:
2003
Part 1: Models and Terminology”
ANSI/ISA-95.00.02:
2010
IEC/ISO 62264-2:
2004
Part 2: Data Structures and Attributes”
ANSI/ISA-95.00.03:
2005
IEC/ISO 62264-3:
2007
Part 3: Activity Models of Manufacturing Operations
Management
ISA draft 95.00.04
-
(Part 4: Object Models and Attributes of
Manufacturing Operations Management)
ASNI/ISA-95.00.05:
2007
IEC/ISO 62264-5:
2010 (APUB)
Part 5: Business to Manufacturing Transactions
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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Benefits and adoption of ISA-95
■ Benefits:
 Direct : Cost and risk reduction of MES and B2M projects
 Indirect :


Improvement of operational performance : CTP, agile manufacturing,
planning feedback, error reduction
Dynamization of IT/Business alignment
■ Adoption:
 Most automation / MES vendors claim their adhesion to ISA95
 ERP vendors ignore it


Noticeable exception: SAP since 2004
B2MML becomes the de facto standard for B2M information
exchange
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
10
Agenda
■
■
■
■
■
■
■
ISA-88 snapshot
ISA-95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
11
CCM global IIPS life cycle
IIPS : Industrial Information Processing Systems
Strategy Guidance
Manage
Master Planning
Execute
Industrial
Architecture
User
Requirements
IIPS
Construction
IIPS
Deployment
IIPS Support
Maintenance
IIPS
Operation
Use
Information Technology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
12
CCM global IIPS life cycle
Information Service Definition
Industrial
Architecture
User
Requirements
IT Resource Development
IIPS
Construction
IIPS
Deployment
IIPS
IIPS Support
Operation
Maintenance
Run-time Information
Processing
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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ISA-95 like IIPS life cycle
Run-time Information Processing
Information Service
Requests
Information Services
Requests
Information
Services
(BP)
Information
Services
(Task)
Information
Services
(implemented)
Information
Services
Capability
Resources
HW, SW, DWH
Information Service Definition
Intelligent
Industrial
Systems
IT Resource Development
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
14
Agenda
■
■
■
■
■
■
■
ISA-88 snapshot
ISA-95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
15
Industrial Architecture Models Purpose
■ Scope
 The entire industrial facility – the Production sub-system within the
Enterprise system
 Spatio-temporal description (structures and interactions) of this subsystem
 The information reality that tights Energy and Matter together
■ Ongoing maintenance
 This module only presents models for describing the facility
 However, the facility is ever changing.

The Industrial Architecture Processes (IAP) integrates IAM within the
global enterprise strategy definition and fulfillment process
■ IAM provides the framework
 For capturing and managing knowledge
 For mastering IIPS development planning
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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ISA-88
Equipment Control
ISA-88 + ISA-95
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
IT Asset Management
Physical Process Control
Human Asset Management
Physical Process Management
Physical Asset Management
ISA-95
Inventory Asset Management
Operations Process Management
Product Asset Management
Industrial Architecture Dimensions
TOGAF
ITIL
17
IIPS Scope in Industrial Architecture framework
Business Information Processing Systems
Marketing, R&D, HR, Engineering, Sales, Purchasing, Finance/accounting, planning
Operations Process Management
Resource & Definitions Management
Scheduling, Dispatching,
Analysis, Performance, Tracking, Reporting
ISA95
Industrial Information Processing Systems
Equipment Control
Basic, Procedural, Coordination Control
Intelligent
Industrial
Systems
ISA88
Physical Process Management
Work Segments & Resources
Physical Process Control
Operating procedures, Routings, Recipes
Production
Inventory, Logistics
Quality
Maintenance
Tooling
…
Risk & Safety
Information
Configurations
Documentation
Regulation
Incidents & Deviations
…
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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Common IT systems involved
ERP
Operations Process Management
Physical Process Management
MES
Physical Process Control
AUTOMATION
Equipment Control
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
19
Agenda
■
■
■
■
■
■
■
ISA-88 snapshot
ISA-95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
20
ISA88 Process model (Processing Requirement)
A Process is made up of an ordered set of one or more Process
Stages
Process
Stage
A Process Stage is made up of an ordered set of one
or more Process Operations
Process
Operation
A Process Operation is made up of an
ordered set of one or more Process
Actions
OPM
Process
Action
PPM
PPC
EC
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
Process
21
Resource models (Structural description)
OPM
PPM
PPC
EC
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
■ The resource asset models (Personnel, Equipment, and Material)
are based on the ISA-95 breakdown.
■ All these resources share a similar pattern. Equipment and Material
are indeed the same entity: A “machine” can be:
 A “Physical Asset” for the company that makes products with it,
 An “Inventory Asset” for the company that makes them (finish
product) or sell / distributes it
22
ISA-95 Material Model
Is assembled from
Is assembled from
0..n
0..n
Defines
a grouping
0..n
Material
Class
Has
properties
of
Is assembled from
0..n
1..1 Defined by
Is tested
by a >
0..n
0..n
0..n
Material
Class
Property
May
map to
0..n
< may contain nested
0..n
Is tested
by a >
0..n
Material
Definition
Property
Material
Sublot
0..n
0..n
Has
values for
Has
values for
May be made up
of sublots
Records the
execution of
0..n
Defines a
procedure
for
obtaining a
0..n
Maps to
0..n
QA Test
Result
0..n
0..n
Material Lot
Property
OPM
PPM
0..n
< may contain nested
0..n
< may contain nested
PPC
EC
Intelligent
Industrial
Systems
0..n
Material Test
Specification
0..n
Is tested
by a >
0..n
Material Lot
Is tested
by a >
0..n
0..n
0..n
Made up of
0..n
Material
Definition
Has
properties
of
Is tested
by a >
0..n
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
Is assembled from
23
ISA-95 extended physical model (Actual Facility layout)
ENTERPRISE
BATCH
PROCESS
(ISA88)
CONTINUOUS
PROCESS
DISCRETE
PROCESS
WAREHOUSE
WORK
CENTER
PROCESS
CELL
PRODUCTION
UNIT
PRODUCTION
LINE
STORAGE
ZONE
WORK UNIT
UNIT
UNIT
WORK CELL
STORAGE
UNIT
SITE
EQUIPMENT
MODULE
OPM
PPM
CONTROL
MODULE
Intelligent
Industrial
Systems
PPC
EC
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
AREA
24
ISA-95 Equipment Model
< May be made up of
0..n
Equipment
Class
0..n
0..n
0..n
Has
properties
of >
Equipment
< Defined by
0..n
Is tested
by an >
Has
values for >
Is tested
by an >
0..n
0..n
Equipment
Capability Test
Specification
Is tested
by an >
0..n
Equipment
Class Property
0..n
0..n
< Records the
execution of
Defines a
procedure for
obtaining an >
Equipment
Capability Test
Result
0..n
0..n
Equipment
Property
Maps to
OPM
PPM
PPC
0..n
< may contain nested
Intelligent
Industrial
Systems
0..n
EC
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
0..n
< may contain nested
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
25
ISA-95 Personnel Model
Has
properties
of >
0..n
0..n
< Defined by
Person
0..n
0..n
Is tested
by a >
Has
values for >
Is tested
by a >
0..n
0..n
Qualification
Test
Specification
0..n
0..n
Personnel
Class Property
Is tested
by a >
0..n
< Records the
execution of
0..n
Defines a
procedure for
obtaining a >
Qualification
Test
Result
0..n
0..n
< Maps to
Person
Property
OPM
PPM
PPC
EC
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
Personnel
Class
26
ISA-88 Procedural Control model (Equipment/Product
Interactions)
A Procedure is made up of an ordered set of one or more Unit
Procedures
Unit
Procedure
A Unit Procedure is made up of an ordered set of
one or more Operations
Operation
An Operation is made up of an ordered
set of one or more Phases
OPM
Phase
PPM
PPC
EC
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
Procedure
27
ISA-95 Segment Model
0..n has an execution dependency on
0..n
Process
Segment
Process
Segment
Dependency
0..n
is a collection of
May be made up of
0..n
0..n
Process
Segment
Parameter
0..n
Equipment
Segment
Specification
Personnel
Segment
Specification
Has properties
of
0..n
0..n
Has properties
of
0..n
Physical Asset
Segment
Specification
Has properties
of
Material
Segment
Specification
0..n
Is assembled
from
Has properties
of
May be made up of
0..n
Personnel Segment
Specification
Property
0..n
Equipment Segment
Specification
Property
Corresponds
to element in
1..1
0..n Corresponds
to element in
1..1
0..n
Physical Asset
Segment
Specification
Property
0..n Corresponds
to element in
1..1
0..n
Material Segment
Specification
Property
0..n Corresponds
to element in
1..1
OPM
Personnel
Model
Equipment
Model
Physical Asset
Model
Material
Model
PPM
PPC
EC
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
0..n
28
ISA-95 Operational Activity Model
1.Detailed
scheduling
8. Resource
management
5. Tracking
2. Dispatching
6. Analysis
4. Data
collection
7. Definition
management
OPM
Production
Other
Quality Control
Inventory
Maintenance
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
PPM
PPC
EC
Product Asset
Inventory Asset
Physical Asset
Human Asset
IT Asset
3. Execution
29
Agenda
■
■
■
■
■
■
■
ISA88 snapshot
ISA95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
30
Production system Lifecycles
Market
Demand
Customer
Orders /
Forecast
Manufacturing
Product R&D
Intelligent
Industrial
Systems
Engineering
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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ISA-88 & ISA-95 models in Production Lifecycles
ISA-88 models
Operations
•Recipe Procedural
ISA-95 models
•Schedule
•Performance
ISA-88 models
•Activity
ISA-95 models
•Activity
ISA-88 models
•Process
•Recipe Procedural
ISA-95 models
•Product Definition
Product development
Intelligent
Industrial
Systems
ISA-88 models
•Physical
•Equipment Procedural
ISA-95 models
•Personnel, Equipment, Material
•Capability, Segment
Engineering
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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ISA-88 & ISA-95 Objects in Production Lifecycles
Schedule
3. Operations
Requests /
Recipes
Segments / RPE
Product
Definition
1. Product
Dévelopment
Intelligent
Industrial
Systems
Segments
PE/RPE
Segments
EPE
Resources
Personnel / Equipment /
Material
Capability
2. Engineering
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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Agenda
■
■
■
■
■
■
■
ISA88 snapshot
ISA95 snapshot
IIPS Lifecycle
CCM modelling framework
ISA-88/95 based Models and Objects
ISA-88/95 in Production Lifecycles
Methodology
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
34
IAM framework definition overview (see IAP)
P&ID
R&D
1b. Physical
Modelling
CCM
Rules &
Tools
2. Equipment
Control
Modelling
Use
Build
Improve
1a. Product
Modelling
1a. Inventory 1c. Human
Modelling
Modelling
Object
classes
and
models
repository
3. Process
Procedural
Modelling
4. Segments
Modelling
5. Operation
Process
Modelling
Intelligent
Industrial
Systems
IT
modelling
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Use
Build
Improve
35
Ongoing Industrial Architecture
P&ID
Goverance
Enabling
CCM
Rules &
Tools
R&D
1b. Physical
Modelling
1a. Product
Modelling
2. Equipment
Control
Modelling
3. Process
Procedural
Modelling
1a. Inventory 1c. Human
Modelling
Modelling
Object
classes and
models
repository
4. Segments
Modelling
Use
Build
Improve
5. Operation
Process
Modelling
Intelligent
Industrial
Systems
Persistence
IT
modelling
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
Use
Build
Improve
36
Exécution
Business
Interactions Hierarchy
Business Processes
Business Activities
(ISA-95,
MES)
Operation Processes
Operation Activities
(ISA-88,
Equipment
Control)
Intelligent
Industrial
Systems
Operating Instructions
Procedural Elements
Physical Processes
Recipes, routing
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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Examples of Description standards
Business / Operation process Description:
BPMN, OSSAD, UML
Schedule
Requests /
Recipes
Product Definition:
PPC
Segments / RPE
Product
Definition
Segments
PE/RPE
Physical Process
Description
: PFC
Segments
EPE
Capability
Resources
Personnel / Equipment /
Material
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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Modular ISA-88/95 structure
Entreprise, Site,
Area, Work
Center, Work Unit
Physical
Breakdown
Production,
Quality, Inventory,
Maintenance
Domains
Decisional
Level
Object Classes
(Templates)
Business Processes,
Operation Processes
Physical Processes
Equipment control
Functionnal
Objects
Run, Stop, Hold…
Exclusive
States
Intelligent
Industrial
Systems
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
39
Information Elements
Domain
Product Asset
Human Asset
Model
Process
Product
Material
Physical
Equipment
Physical Asset
Personnel
Equipment Control
Procedural
ISA-95
ISA-88
Physical Process
Control
Procedural
ISA-88
Inventory Asset
Equipment Asset
Physical Process Mngt Segment
Operation Process
Operation
Mngt
Activity
Intelligent
Industrial
Systems
Std
ISA-88
ISA-95
ISA-95
ISA-88
ISA-95
Information elements
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
ISA-95
ISA-95
1_12_ISA8895_Overview_Introduction_Modeling_v2_en.pptx
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Thank You !
Intelligent
Industrial
Systems
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