Practical Enterprise Modelling:

ISA 88 and ISA 95 standards

IEC SB3 Sponsored Seminar
Workshop on Industrial Automation Objects
3-4 April 2001, Geneva, Switzerland
Jean Vieille, Consultant
ISA SP88 & SP95 committees member
jean-vieille@usa.net

Agenda
ISA 88 and 95 in SCM and Production Scheduling
ISA 95 : Enterprise-Production Communication
ISA 88 : Modular Control

ISA 88 and 95 in SCM and Production

Scheduling

Market / Customer driven production

Classical Enterprise

Market /
Customer
demand

Production
Schedule

Product
Development

Resources
Engineering

Agile Enterprise
Market /
Customer
demand

Production
Schedule
Production
Schedule

Resources
Engineering

Product
Develoment

Enterprise
System 1

Manufacturing
Control System 1
Manufacturing
Control System 2

Enterprise
System 2
Company 2 with No manufacturing

Company 1 with
manufacturing

Manufacturing
Control System 3
Company 3 Contract manufacturer

S95.01 Scope

Business Logistics
Business Planning & Logistics
Systems
Interface
addressed
(ERP)
in ISA 95.01 / 02

Level 4

Plant Production Scheduling,

Operational Management, etc

Level 3

Manufacturing
Operations & Control

Manufacturing
Operations Support
Levels
(MES)
2,1,0
Discrete
Continuous
Batch

dS95.03 Area

Dispatching Production, Detailed Production

Scheduling, Reliability Assurance, ...

Control
Systems

Control
Systems

Control
Systems

Source: ISA dS95.01 Enterprise/Control System Integration

S88

Manufacturing in The Supply Chain

The Supply Chain
The network of activities in a company that take place from
customer order to customer delivery
Delivery
Delivery

OrderEntry
Entry
Order

Scheduling
Scheduling

Suppliers
Suppliers

Customer

Suppliers
Suppliers

Production
Production

Suppliers
Suppliers

Distribution
Distribution

Enterprise Resource Planning / Supply Chain Management

Materials
Product Production Manufacturing
Operations
Purchasing Development Planning

Distribution
& Logistics

Customer
Order
Management Service

SP95.01 Enterprise / Control System Integration

R

R
C

Recipe
Management

Production
Planning and
Scheduling

E
P

Order &
Inventory
Management

Production
Information
Management

Process
Management

Unit
Supervision

Process
Control

Process Management

Maintenance
Management

E
P

Warehouse &
Transportation
Management

Consumers

Suppliers

S95/S88 and The Supply Chain

S88 et S95
Enterprise A
Product

Enterprise B
Product

S88

S88
S95

Enterprise X
Manufacturing
S88
Process
Cell X1

Quality

S88
Process
Cell X2

S95

Maintenance

Enterprise Y
Manufacturing
S88

S88

Process
Cell Y1

Process
Cell Y2

S95.01 Production Schedule Structure

Production Schedule
A Production Schedule is made
up of 1..n Production Requests

Production Request
A Production Request is made up
of 0..n Segment Requirements

Segment Requirement
A Segment Requirement may
contain 0..n of each

Production Personnel
Parameter Requirement

Material
Material
Equipment
Consumed
Produced
Requirement Requirement
Requirement

Consumable
Expected

Mixed Format Schedule Application

S95.01
Production
Schedule

Work
Dispatching

Setpoints
&
Flowpaths

Continuous
Premix

S88.02
Schedule
Entry

Setup
Instructions

Batch Production Discrete

Process
Packaging

S95 in Production System Lifecycles

Production
Schedule

Segment
Requirement
Product
Definition

Product
Development

Product
Segments

Process
Segments

Resources

Production
Capabilities

Resources
Engineering

S88 in Production System Lifecycles

Production
Schedule

S88 : Schedule

S88 : Resources

S88 : Recipe

Product
Development

S88 : Equipment
Procedural
Elements

Resources
Engineering

ISA 95 : Enterprise Production

Communication

What is ISA95 ? Status

SP95 committee started in October 1996
ANSI/ISA95.00.01 available from ISA
Submitted to IEC/ISO
Joint Working Group (JWG 15) to be established

ISA 95.00.02 in draft, out for vote

Out for committee ballot and public comment

ISA 95.00.03 in draft

Still under development in the committee

World Batch Forum

Developing XML Schemas for the exchanged information

Some SP95 Committee Members / Supporters

Users

Eli Lilly
DuPont
Dow Corning
Rohm & Haas
Bayer
IBM
Merck
Nestle
UOP
Vendors

ABB
AspenTech
Siemens BaseTen
SAP
Sequencia
InCode Wonderware
ABB
Rockwell Yokogawa Foxboro Propack Data
Honeywell FRSI
InCode Oracle
Marcam
OSI
Intellution Schneider Electric
GSE SystemHP
IBM GS Microsoft ORSI
General
Purdue
MESA
KPMG

Lyondell Chemical Lubrizol

Ben & Jerry's
Novo Nordisk
Bechtel
Sterling Tava Technologies EastmanK
Aurora Biosciences Genemtech
PharmaciaProcter&Gamble

Fluor Daniels
AMR
Jacobs
PDXI
NAMUR Keops
MIT
PWC LLC

Why Did We Start SP95 ?

Integration of business (logistics)
systems to manufacturing is
hard to do
Different systems, cultures, terminology...
Many benefits expected from standardization and documentation of
best practices

Effective operation of manufacturing is hard

to do

MES solutions are too related to processing methods and too industryspecific
Many benefits expected from standardization and documentation of
best practices

Business Defines the Need

There must always be a business need for information
to be exchanged
Requirements for exchanged information are always
driven by business needs & business processes
Typical Business Drivers:

Available To Promise
Reduced Cycle Time
Supply Chain Optimization
Asset Efficiency
Agile Manufacturing

How Does S95* Help?

Alternate Logistics Strategies

Separate the business

processes from the
manufacturing processes
Allow changes in production
processes without requiring
unnecessary changes
scheduling and logistics
processes

Make
to
Order

Make
to
Stock

Engineer Configure
to
to
Order
Order

S95.01

Provide a clear demarcation

of responsibilities and
functions
Provide a clear description
of exchanged information

PDXI
NAMUR

S88.01

SME

Continuous
Manufacturing
Models

Batch
Manufacturing
Models

Discrete
Manufacturing
Models

Alternate Manufacturing Strategies

* S95 is used as a short form for ANSI/ISA95

Scope of S95.01
The definition of the scope of the manufacturing control
domain
A definition of the functions associated with the
interface between control functions and enterprise
functions
A definition of the information which is shared between
control functions and enterprise functions
Based on the Purdue Reference Model for CIM and
MESA model

En Ma
er te
gy ria
In l a
ve nd
nt
or
y

Pro Standa
ces
s D rds
ata
QA
Res
ults

From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org

Quality
Assurance
(6.0)

Research
Development
and Engineering

d
an
s
rd er s
da om nt
an st me
St Cu ire
qu
Re

Material and
Energy Control
(4.0)

Process Data
In-Process
Waiver Request

s
es
oc
Pr
nd ow
ta H
s
uc ow
es
od n
oc s t
K
Pr
Pr que
nd e
ta nR
uc tio
od a
Pr form
In

nd
al a r
teri
rde
Ma rgy O nts
e
Ene uirem
q
Re

ing n
om
Inc rmatio
nf i
Co

d
an s
l
i a t.
er en
t
a
M i re m
u
m
er eq
tr T y R
o rg
Sh ne
E

Production
Control
(3.0)

Product
Inventory Control
(7.0)
QA
Res
ults

an
Pl
y
cit
om
pa n Fr e
l
Ca
io
ct edu
du ch
S

o
Pr

Procurement
(5.0)

Maintenance Purchase
Order Requirements

Product Cost
Accounting
(8.0)

Rele
a
To S se
hip

Pack Out
Schedule

Product
Shipping Admin
(9.0)
Con
fi
To S rm
hip

Finished Goods
Inventory

Fin
is h
e
W dG
aiv oo
er ds

Pr
od
uc
Re Proc t an
qu es d
ire s
me
nts

Production
Scheduling
(2.0)

Order
Processing
(1.0)

Pr
od
uc
Ob tion
Pr
jec Co
od
tiv st
uc
es
tio
an n P
d er
Co fo
st rm
s
an
ce

Lo
Ma
t
En ng T
Re erial a
er erm
cei
gy
pt ( nd E
Re Ma
Inc ner
t
qu er
om gy
ire ial
ing
m an
)
en d
t.s

SP95.01 Enterprise / Control

Functional Model (PRM)

Marketing
& Sales

Elements of Models & Definitions

Domain
Definitions
(Responsibility)

Functions
in Domains

Functions
of Interest

Information
Definitions

Categories of
Information

Information
Flows of Interest

Identified Information Categories

Data flow
information was
categorized
Multiple Venn
diagrams used to
illustrate the
overlap of
information
categories

Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Production Product
Production Production
Capability Definition
Schedule Performance
Information
(What was
Information (What to
(What is
available
for use)

(How to make
a product)

make and
use)

made and
used)

Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc

Major Object Definitions

Resources

Capability, Product, Production

Product

People

Equipment

Materials

Segments

Time

Capabilities

Product
Definitions

Production
Schedule

Production
Performance

Four Resource Object Models

Personnel resources managed for production
People

Equipment resources managed for production

Equipment

Material resources managed for production

Materials

Business view of production processes

Process Segments

Material Definition Example

Common material information
Material Class
Acid
l
ia
er
at ss
M la
C

pH

Density

Material Definition
HCl 50%

Lot
HCL-50-100019

Sublot
HCL-50-100019
Barrel 15

l
ia
er
at ition
M in
f
De

Color Purity

QA Test
Results

pH
7.0

Location
QA Test
Specification

Density Color Purity

1.32 Yellow .5%

Process Segments
Business view of production

Assembly

Paint

Inspect

I-Beam
Laborer
3x
8 hour

Type =
Stainless
Steel

Inspector
2x
.25 Hour

Mixing
Cans

Rollers
Certified
Painter =
TRUE

Capability, Product, and Production

Information
What is available for use for production
Product

Time

Capabilities

What is needed to make a product

Product
Definitions

What to make and resources to use

Production
Schedule

What was made and resources actually used

Production
Performance

Capability Models
Product

People

Equipment

Materials

Segments

Time

Capabilities

Syst

Per Product Definitions

Scheduling
System
Bill Of Resources
e.g. 10 Speed Bicycle
Product
Segments

f
ll O ces
i
B ur
so
Re

Frame
Assembly

Bill Of Materials
e.g. 10 Speed Bicycle

Final
Assembly

Paint

Color
Frame
Type

Seat
Height

ll
Bi

f
O

ls
ia
er
t
a
M

Production Rules
e.g.
10 Speed Bicycle
y
bl
m ns
e
s
io
As ruct
t
s
In

Manufacturing
System

Manufacturing
Bill
Frame : 1
Wheels : 2
Chain : 1
Seat : 1
Handlebars :1
Brake Pads : 4
...

Production Schedule
People

Equipment

Materials

Segments

Product
Definitions

Production
Schedule

Production Performance
People

Equipment

Materials

Segments

Product
Definitions

Production
Schedule

Production
Performance

Four Models & Segment Resources

Production
Capability

Process
Specification

Product
Definition

Production
Scheduling

Production
Information

What resources
are available

What can be done

with the resources

What must be defined

to make a product

What is it to be
made & used

What was
made & used

Production
Schedule

Production
Performance

Production
Rule

Production
Request

Production
Response

Production
Capability

Process
Segment

Product
Segment

Segment
Requirement

Segment
Response

Resource
Capability

Resource
Segment
Capability

Resource
Specification

Resource
Requirement

Resource
Actual

Capability
Property

Segment
Property

Specification
Property

Requirement
Property

Actual
Property

ISA 95.00.02 : Relationship with Part 1

ISA95.01
Equipment
model

dISA95.0
2
Equipmen
t
Attributes

Attribute
Name

ID

Description

A unique identification of a specific piece of R7726

equipment, within the scope of the information
Reactor 101
exchanged (Production Capability, Production
Lathe machine 33
Schedule, Production Performance, )
The ID is used in other parts of the model when
the equipment must be identified, such as the
production capability for this person, or a
production response identifying the equipment.

Description

Examples

Additional information about the equipment.

ISA 95.00.03 : Level 3 Functions

MESA Definitions
Operations and Detailed Scheduling
Production Tracking
Dispatching Production
Resource Allocation and Control
Data Collection and Data Acquisition
Quality Management
Process Management
Performance Analysis
Interface to
Document Control
Labor Management
Maintenance Management

d95.03 Definitions
Detailed Production Scheduling
Production Tracking
Production Dispatching
Resource Management
Historical Data Management
(QA) Product Analysis
Process Analysis
Production Analysis
Product Definition Management
Process Monitoring
Manual Operations
Automated Control

d95.03 Manufacturing Operations Functions

Product
Definitions

Production
Capability

Production
Schedule

Production
Performance

Detailed
Production
Scheduling

Production
Tracking

Resource
Management

(QA) Product
Analysis

Production
Dispatching
Historical
Data
Management

Product
Definition
Management

Production
Execution
Process
Monitoring

Manual
Operations

Process
Analysis
Production
Analysis

Automated
Control

ISA 88 : Modular control

What is ISA 88 ? - Status

Standard ANSI/ISA 88 Batch Control
Comit SP88 lanc en 1988
Partie 1 ISA 88.00.01
Publie et disponible lISA et lANSI
IEC 61512-1 bilingue disponible auprs de lIEC, lUTE et lAFNOR

Partie 2 ISA 88.00.02

Publication imminente
Version IEC (61512-2) bilingue pour 2001?

Partie 3 ISA 88.00.03

Dbut des travaux

Automation Challenge
Flexibility

Ideal automation

Manual
Operation

Darin Flemming
Lou Pillai

S88

Capability

Traditional
Automation

Complexity

The Powerful Tyrex

Big brain
Centralized design
OK for steady / slow changing
environment
Shortcomings
Agility
Availability

Refer to first computerized systems

vs Stupid Bird
Limited intelligence
Mostly decentralized design
Local decision making at feather
level
Cope well with unexpected
situations
Inherently adaptative structure

From Goal to Labor

Forecasting,
Planning
And Scheduling

Process
Control
Definition

Equipment
Functional
Capabilities

The Goal:
I know
What/How
To do

Flying
chirping
Eating
Love.

Walking

Elementary
Equipment
Control

Scheduling hierarchy
Business system
ISA 95
MES systems
SCADA systems

Process
Control

Equipment
Control

Intelligent
Device

ISA 88
IEC 61512
OPC

IEC 61131
IEC 61499
IEC 61158
Fieldbus

Product Processing / Equipment Control

Equipment
allocation

Process
Control
Production
schedule

How to make
the product
using
available
services?

Equipment
Control
How to provide
the expected
services
taking care of
safety ?

ISA 88

R&D

ISA 88.00.02
(PFC)

IEC 60848
IEC 61131
IEC 61499
IEC 61508
IEC61158

ISA 88 Physical Model

Enterprise
May contain

Site
May contain

Area
May contain

Process Cell
Must contain

Unit
Equipment

May contain

Equipment Module
May contain

Control Module

May contain

May contain

Equipment Entities -An Object Approach

Physical
Equipment
Equipment
Entities

Equipment
Control

Instruments
Basic control
Coordination control
Procedural control

Example of physical modeling

Process Cell
Unit
EM

Unit

EM

EM

EM
CM
CM

CM

CM

CM

CM

Example of control modules

CM4

CM2
CM1

D1
PID

D4
D3
PID

PID

CM3
D5
D2

HIC

HIC

Why Control Modules

Treating as a control module simplifies
the interface to this group of objects
Commands

Status

Circulate

Circulating

Pump to
Process

Pumping
to Process
Stopped
FO

Stop
Shutdown

FC
Pump

Shutdown

Recipe/Equipment Control Separation

Equipment
Control

Control Recipe
Procedure
Recipe
Procedure

[Must Always Exist]

Procedure
is an
ordered set of

Unit
Procedure
is an
ordered set of

Operation
is an
ordered set of

Phase

Equipment
Phase

Recipe/Equipment Control Separation

- Typical
Equipment
Control

Control Recipe
Procedure
Recipe
Procedure
is an
ordered set of

Recipe Unit
Procedure
is an
ordered set of

Recipe
Operation
is an
ordered set of

Recipe
Phase

References

Equipment
Phase

Recipe/Equipment Control Separation Alternate 3

Equipment
Control

Control Recipe
Procedure
Recipe
Procedure

References

Equipment
Procedure
is an
ordered set of

Equip. Unit
Procedure
is an
ordered set of

Equipment
Operation

is an
ordered set of

Equipment
Phase

Phase Interface Logic

State machine enforcement between recipe phase and
equipment phase
A set of services that support commands to the
equipment phase
A set of services that support requests from the
equipment phase to the recipe phase
Recipe
Phase

Phase
Interface
Logic

Equipment
Phase

Phase Interface Logic

Requests

Parameters

Commands

State
Machine

States

Phase Object
Parameters

Data

Start
Hold

Run
Held

Pause
Stop
Abort

Aborting

Reset
Resume
Restart

Holding

Control
Action
Status

Paused
Stopped
Aborted

Pausing

Running

Stopping

Idle
Completed

Data
Collection
Requirements

Restarting
Control
Steps

Example Procedural Element States

Restart
Complete

Held

Restarting

Holding

Reset
Hold
Idle
(Initial
State)

Start

Pause

Running

Resume

Abort Stop
Aborting

Aborted
Reset

Pausing

Stopping

Stopped
Reset

Paused

Final States
Quiescent States
Transient States

Exception Handling In Control Actions

The safety interlock logic takes precedence over
phase logic or process interlock logic. Typically this
logic, when required, is implemented in an
independent safety interlock system.

Safety
Interlock

Control Module

Process
Interlock

Control Module

Exception Logic

The process interlock logic takes precedence

over phase logic and manual override logic.
Typically, this logic is implemented in the
DPCS.

Phase
Logic

Control step (command)

Control
Action

Control Module/Control
Action State/Mode

Equipment Module

Control Module

Inhibit manual override

(Interlock from phase logic),
Also sent to console to inhibit
choice of manual mode

Console
Control
Control Module/Control
Action State/Mode

Field I/O

Exception Logic

Inputs to Control Action Logic:

- Set manual mode
- Command from operator's
console

ISA 88.00.02 : Procedural Function Chart

Unit procedure interactions
Relative timing
Tank
A, B or C

P r e p a r a tio n
S1

R e a c to r
1 or 2
o p e r a t o r in p u t
= O K to s ta r t

R e a c tio n

Synchronization points

Arrowheads indicate material transfer

Multiple levels of procedures

Encapsulation (contents) of unit procedure revealed

Provides more detail

S1

T1

Height of unit procedure symbol

Vertical placement of symbols
Master recipes do not contain absolute timing

T1

THANK YOU