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 Resources
Development Engineering
 Agile Enterprise
Market /
Customer Production
demand Schedule

Production
Schedule
Resources
Product Engineering
Develoment

Enterprise Manufacturing
System 1 Control System 1 Company 1 with
manufacturing
Manufacturing
Control System 2

Enterprise Manufacturing
System 2 Control System 3
Company 2 with No manufacturing Company 3 Contract manufacturer
S95.01 Scope

Business Logistics
Level 4
Business Planning & Logistics
Systems
Plant Production Scheduling,
Operational Management, etc
Interface addressed
(ERP) in ISA 95.01 / 02
Level 3
Manufacturing
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
dS95.03 Area

Operations Support
Scheduling, Reliability Assurance, ...
S88
Levels
2,1,0
Continuous
(MES)
Discrete Batch
Control Control Control
Systems Systems Systems

Source: ISA dS95.01 Enterprise/Control System Integration

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

Order Entry Delivery

Suppliers Customer

Scheduling Suppliers Production Distribution

Suppliers
 S95/S88 and The Supply Chain

Consumers
Enterprise Resource Planning / Supply Chain Management
Suppliers

Materials Product Production Manufacturing Distribution Order Customer

Purchasing Development Planning Operations & Logistics Management Service

SP95.01 Enterprise / Control System Integration

R R R
C Production C C
Recipe Production
Management Planning and Information
Scheduling Management
E A E A E A

P Process P P
Management

Order & Maintenance Warehouse &

Inventory Management Transportation
Management Unit
Supervision Management

Process
Control

Process Management
S88 et S95
Enterprise A Enterprise B
« Product » « Product »

S88 S88

S95

Enterprise X Quality Enterprise Y

« Manufacturing » « Manufacturing »
S88 S88 S88 S88
S95
Process Process Process Process
Cell X1 Cell X2 Cell Y1 Cell Y2

Maintenance
 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 Equipment Material Material Consumable

Parameter Requirement Consumed
Requirement Requirement Produced Expected
Requirement
Mixed Format Schedule Application
S95.01
Production
Schedule

Work
Dispatching

Setpoints S88.02
Setup
& Schedule
Instructions
Flowpaths Entry

Continuous Batch Production Discrete

Premix Process Packaging
S95 in Production System Lifecycles
Production
Schedule

Segment
Requirement

Product Product Process Production

Definition Segments Segments Capabilities

Product
Development Resources
Resources
Engineering
S88 in Production System Lifecycles
Production
Schedule

S88 : Schedule

S88 : Resources
S88 : Recipe
S88 : Equipment
Procedural
Elements
Product Resources
Development 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 Lyondell Chemical Lubrizol
 Dow Corning Ben & Jerry's Novo Nordisk Bechtel
 Rohm & Haas Sterling Tava Technologies EastmanK
 Bayer IBM Aurora Biosciences Genemtech
 Merck Nestle Pharmacia Procter&Gamble
 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 Fluor Daniels AMR Jacobs
 MESA PDXI NAMUR Keops
 KPMG 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
industry-specific
 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?
 Separate the business Alternate Logistics Strategies
processes from the Make Make Engineer Configure
manufacturing processes to to to to
Order Stock Order Order
 Allow changes in production
S95.01
processes without requiring
unnecessary changes PDXI
S88.01 SME
NAMUR
scheduling and logistics
processes Continuous Batch Discrete
 Provide a clear demarcation Manufacturing
Models
Manufacturing
Models
Manufacturing
Models
of responsibilities and Alternate Manufacturing Strategies
functions
 Provide a clear description
of exchanged information
* 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
SP95.01 Enterprise / Control
Order
Functional Model (PRM) Processing
(1.0)
Product
Shipping Admin
Production Product Cost (9.0)
Scheduling Accounting
(2.0) (8.0)

Product
Inventory Control
(7.0)

Maintenance Purchase Production

Procurement Order Requirements Control
(5.0) (3.0)

Quality
Assurance
(6.0)
Material and
Energy Control
(4.0)
Marketing
& Sales
Research
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org Development
and Engineering
Elements of Models & Definitions
Domain Functions Functions
Definitions in Domains of Interest
(Responsibility)

Information Categories of Information

Definitions Information Flows of Interest
 Identified Information Categories
 Data flow
information was Enterprise Information
categorized Plant Production Scheduling,
Operational Management, etc

 Multiple Venn Production Product

Production Production
diagrams used to Capability Definition
Schedule Performance
illustrate the InformationInformation (What to (What was
overlap of (What is
available
(How to make make and made and
information for use)
a product) use) used)

categories
Manufacturing
Control Information
Area Supervision, Production Planning,
Reliability, Assurance, etc
Major Object Definitions
Resources Capability, Product, Production

Product
Time
People
Capabilities

Product
Equipment Definitions

Materials Production
Schedule

Production
Segments 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 Material Definition Lot Sublot

Acid HCl 50% HCL-50-100019 HCL-50-100019
Barrel 15

pH Density Color Purity QA Test QA Test Location

Results Specification

pH Density Color Purity

7.0 1.32 Yellow .5%
Process Segments
 Business view of production

Assembly Inspect Paint

I-Beam
Laborer
3x Inspector Mixing Rollers
8 hour Type = 2x Cans
Stainless .25 Hour Certified
Steel 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
Time
People
Capabilities

Equipment

Materials

Segments
 Per Product Definitions
Scheduling Material
System System
Bill Of Resources Bill Of Materials
e.g. 10 Speed Bicycle e.g. 10 Speed Bicycle

Product
Segments

Manufacturing
Bill
Frame : 1
Production Rules
Wheels : 2
e.g.
Chain : 1
Paint 10 Speed Bicycle
Frame Final Seat : 1
Assembly Assembly Handlebars :1
Brake Pads : 4
Color ...
Frame Seat Manufacturing
Type Height
System
Production Schedule

People

Equipment Product
Definitions

Materials
Production
Schedule

Segments
Production Performance

People

Equipment Product
Definitions

Materials
Production
Schedule

Production
Segments
Performance
Four Models & Segment Resources
Production Process Product Production Production
Capability Specification Definition Scheduling Information
What resources What can be done What must be defined What is it to be What was
are available with the resources to make a product made & used made & used

Production Production
Schedule Performance

Production Production Production

Rule Request Response

Production Process Product Segment Segment

Capability Segment Segment Requirement Response

Resource
Resource Resource Resource Resource
Segment
Capability Specification Requirement Actual
Capability

Capability Segment Specification Requirement Actual

Property Property Property Property Property
ISA 95.00.02 : Relationship with Part 1

ISA95.01
Equipment
model

Attribute Description Examples

Name

dISA95.02 ID A unique identification of a specific piece of R7726

equipment, within the scope of the information Reactor 101
Equipment exchanged (Production Capability, Production
Schedule, Production Performance, …) Lathe machine 33
Attributes 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 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 Production Production Production

Definitions Capability Schedule Performance

Detailed
Production
Scheduling

Resource Production
Management Tracking
Production (QA) Product
Dispatching Analysis

Product Historical
Process
Definition Data
Management Management Analysis

Production
Execution Production
Analysis

Process Automated
Monitoring Control
Manual
Operations
ISA 88 : Modular control
What is ISA 88 ? - Status
 Standard ANSI/ISA 88 « Batch Control »
 Comité SP88 lancé en 1988
 Partie 1 – ISA 88.00.01
 Publiée et disponible à l’ISA et à l’ANSI
 IEC 61512-1 bilingue disponible auprès de l’IEC, l’UTE et l’AFNOR
 Partie 2 – ISA 88.00.02
 Publication imminente
 Version IEC (61512-2) bilingue pour 2001?
 Partie 3 – ISA 88.00.03
 Début des travaux
Automation Challenge
Ideal automation

Flexibility
S88

Manual
Capability
Operation

Darin Flemming
Traditional Complexity
Lou Pillai
Automation
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, Process Equipment Elementary
Planning Control Functional Equipment
And Scheduling Definition Capabilities Control

The Goal:

I know
What/How
To do

Flying

chirping
Walking
Eating

Love.
Scheduling hierarchy
Business system

ISA 95
MES systems
SCADA systems
ISA 88
IEC 61512
Process OPC
Control

Equipment
IEC 61131
Control
IEC 61499

IEC 61158
« Intelligent »
Fieldbus
Device
Product Processing / Equipment Control
Equipment
allocation

Process Equipment
Control Control
Production •How to provide
schedule • How to make the expected
the product… services…
•… using ISA 88 • … taking care of
available safety ?
services? IEC 60848
R&D IEC 61131
IEC 61499
ISA 88.00.02 IEC 61508
(PFC) 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
May contain

Control Module May contain

Equipment Entities -An Object Approach

Physical
Equipment

Equipment
Entities
Instruments
Equipment Basic control
Control Coordination control
Procedural control
Example of physical modeling

Process Cell

Unit Unit

EM EM EM

EM

CM

CM CM CM CM CM
Example of control modules
CM4

CM2
D4
CM1 PID
D1 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 Pumping
Process to Process

Stop Stopped
FO

Shutdown Shutdown
FC
Pump
Recipe/Equipment Control Separation

Control Recipe Equipment

Procedure Control
Recipe Procedure
Procedure
is an
[Must Always Exist] ordered set of
Unit
Procedure
is an
ordered set of

Operation
is an
ordered set of
Equipment
Phase Phase
Recipe/Equipment Control Separation
- Typical

Control Recipe Equipment

Procedure Control
Recipe
Procedure
is an
ordered set of
Recipe Unit
Procedure
is an
ordered set of
Recipe
Operation
is an
ordered set of
Recipe References Equipment
Phase Phase
Recipe/Equipment Control Separation -
Alternate 3

Control Recipe Equipment

Procedure Control
Recipe References Equipment
Procedure 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
Phase
Recipe Equipment
Interface
Phase Phase
Logic
Phase Interface Logic

Parameters Requests

Commands State States

Machine
Phase Object

Parameters Data

Start Run
Hold Held
Pause Paused
Aborting Pausing
Stop Stopped
Abort Aborted
Reset Idle
Resume Holding Stopping Data Completed
Running Collection
Restart
Requirements

Restarting
Control
Action Control
Status Steps
Example Procedural Element States

Restart
Complete Restarting Held Holding

Reset
Hold
Idle Start Pause
(Initial Running Pausing
State)
Abort Stop Resume

Aborting Stopping Paused

Final States
Aborted Stopped
Reset Quiescent States
Transient States
Reset
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 Control Module
Interlock
Exception Logic

Process Control Module

Interlock
The process interlock logic takes precedence
over phase logic and manual override logic.
Typically, this logic is implemented in the
DPCS.

Control step (command)

Phase Control Field I/O
Logic Action
Control Module/Control
Equipment Module Action State/Mode Control Module

Inhibit manual override

(Interlock from phase logic),
Also sent to console to inhibit Inputs to Control Action Logic:
choice of manual mode - Set manual mode
- Command from operator's
Console console
Control

Control Module/Control Exception Logic

Action State/Mode
ISA 88.00.02 : Procedural Function Chart
 Unit procedure interactions
Tank
 Relative timing
 Height of unit procedure symbol
A, B or C

 Vertical placement of symbols

Preparation
Reactor
S1
1 or 2

Initialize
operator input
= OK to start
 Master recipes do not contain
Reaction
absolute timing
 Synchronization points
Charge

S1
Sample S1
Initialize

 Arrowheads indicate material

Sample
OK
Transfer to Receive
T1 T1

transfer
Reactor T1 T1 from Prep.

React

 Multiple levels of procedures

 Encapsulation (contents) of unit
Transfer to
Storage

procedure revealed
 Provides more detail
THANK YOU