Manufacturing Operations
Management
Dennis Brandl
BR&L Consulting
Dennis Brandl
Peter Owen
Eli Lilly & Co
1
Objectives
• Review the ISA 95 standards and how they are being
used in companies like Eli Lilly & Company for shop
floor to top floor integration
– The standards provide a formal model for exchanged data
between business systems and manufacturing systems
– The models provide a definition of Manufacturing Operations
Management, the activities on the shop floor that take
production schedules and perform the actual work required
to manufacture products and provide visibility of production
• The Manufacturing Operations Management models
are currently being used in the development of
multiple new manufacturing facilities
Dennis Brandl & Peter Owen
2
Manufacturing in the Supply Chain
• “Make” is a significant part of the supply chain and
collaborative manufacturing, but is often the last
element to be actually integrated
– Collaboration in “Make” is usually not a “Low Hanging Fruit”
– But can offer very high ROI for high volume, or high cost
products
• However, Business IT and Manufacturing IT
organizations are often at odds as they try to
collaborate
– They have different goals and different success criteria
– They use the same terms for different elements and different
terms for the same elements
Dennis Brandl & Peter Owen
3
Collaborative Manufacturing Help
• Fortunately there are multiple standards in
place to help integrating business systems
with manufacturing systems.
– The ISA 95 Enterprise/Control System Integration
standards, also an IEC/ISO standard
– XML Schemas standards for collaborative
manufacturing from the World Batch Forum
• Will show how they are being applied to the
development of manufacturing systems
roadmap
Dennis Brandl & Peter Owen
4
Different Points of View
• Business Systems
– Time Horizons
• Long-term view
– Model detail
• Linear route structures
– Control emphasis
• Product cost and overall
profitability
– Modeling criteria:
• Accounting reference
points
• Has inventory value
changed significantly? If
not, don’t model
separately
– View from the boardroom
Dennis Brandl & Peter Owen
• Manufacturing Systems
– Time Horizons
• Real-time view
– Model detail
• Complex routes with
rework paths
– Control emphasis
• Physical movement &
accountability
– Modeling criteria:
• material movement
reference points
• Does product stop
moving? If not, don’t
model separately
– View from the workcenter
5
Philosophical Orientation
• Enterprise Management systems:
– How much is my stuff worth?
– How much stuff do I have/need?
• Manufacturing Operations Systems:
– How do I make my stuff?
– Where is my stuff?
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6
ISA 95 Provides Direction
• The ANSI/ISA 95.00.01 “Enterprise - Control
System Integration - Part 1: Models and
Terminology”
– Also Draft International Standard ISO/IEC 62264-1
• ANSI/ISA 95.00.02 “Enterprise - Control
System Integration - Part 2: Object Attributes”
• Draft ISA 95.00.03 “Enterprise - Control
System Integration - Part 3: Activity Models of
Manufacturing Operations Management”
Dennis Brandl & Peter Owen
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ISA 95 Control Hierarchy Levels
Level 4
Level 3
Level 2
Level 1
Level 0
Dennis Brandl & Peter Owen
Business Logistics
Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
Manufacturing
Operations Management
Dispatching, Detailed Production
Scheduling, Production Tracking, ...
Batch
Production
Control
Continuous
Production
Control
Interface addressed
in the ISA 95.01 and
ISA 95.02 standard
Area addressed
in the ISA 95.03
standard
Discrete
Production
Control
The production processes
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ISA 95 Control Hierarchy Levels
Business
Logistics
Business Logistics
Level 4
Management
Interface addressed
(ERP)
in the ISA 95.01 and
ISA 95.02 standard
Manufacturing
Area addressed
Manufacturing
Operations Management
Level 3
in the ISA 95.03
standard
Operations Management
(MES, LIMS, AM, …)
Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
Dispatching, Detailed Production
Scheduling, Production Tracking, ...
Level 2
Level 1
Level 0
Dennis Brandl & Peter Owen
Batch
Production
Control
Continuous
Production
Control
Discrete
Production
Control
The production processes
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ISA 95 Part 1 and Part 2
Exchanged Information
Information that crosses the boundary between
business systems and manufacturing systems
Dennis Brandl
10
Exchanged Information Categories
Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Production Product
Production Production
Capability Definition
Schedule Performance
InformationInformation (What to
(What was
(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
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11
4x4 Object Models
• Four categories of resources
–
–
–
–
Personnel
Equipment
Material (and Energy)
Process Segments
• Four Process, Product, & Production Models
–
–
–
–
Capability & Capacity Definition
Product Definition
Production Schedule
Production Performance
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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
Dennis Brandl & Peter Owen
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Capability, Product, Schedule, and
Performance Information
What is available for use for production
Product
Time
Capability/Capacity
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
Dennis Brandl & Peter Owen
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Production Schedule
People
• Production Schedule
• Production Request
• Segment Request
• Expected Produced Material
• Expected Consumed Material
• Expected Personnel
• Expected Equipment
• Production Parameters
•…
What to make
- Priority and/or dates
- What materials to use
- What equipment to use
- What personnel to use
- Production parameters
(e.g. Color, Options,…)
Equipment
Materials
Segments
Dennis Brandl & Peter Owen
Production
Schedule
Per location (Site, Area, …)
Per week, day,
shift, order, …
15
Production Performance
People
• Production Performance
• Production Response
• Segment Response
• Produced Material Actual
• Consumed Material Actual
• Personnel Actual
• Equipment Actual
• Production Data
•…
Equipment
What was made
- What material was
actually produced
- What materials were
actually consumed
- Equipment used
- Personnel used
- Production data
(e.g. Purity, density,…)
Materials
Segments
Dennis Brandl & Peter Owen
Production
Performance
Per location (Site, Area, …)
Per shift, hour,
end of batch, …
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XML Standard for B2M Exchanges
• The World Batch Forum has developed XML
Schemas that map to the ANSI/ISA-95
models
• Defines how to represent the ISA-95
information in XML
– Business To Manufacturing Markup Language
– B2MML V2.0
• One schema for each object model
• Formal way to exchange information
– www.wbf.org
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An XML Example – Material Lot
<Material
<MaterialLot>
<ID> W89 </ID>
<Description> A lot of material </Description>
<MaterialDefinitionID> WXE908 </MaterialDefinitionID>
<Location> Tank 1 </Location>
<Quantity
UnitOfMeasure = "KL" > 4500
</Quantity>
<MaterialLotProperty>
<ID> dateTimeProduction </ID>
<Value> 2001-01-06T00:14:23+11:30 </Value>
</MaterialLotProperty>
<MaterialLotProperty>
<ID> Quality Status </ID>
<Value> Good </Value>
</MaterialLotProperty>
</MaterialLot>
</Material>
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ISA95 Part 3
Activity Models of
Manufacturing Operations
In Development
Expected Release 2004
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Order
Processing
(1.0)
Production
Scheduling
(2.0)
Material and
Energy Control
(4.0)
Production
Control
(3.0)
INVENTORY
OPERATIONS
Product
Inventory Control
(7.0)
QUALITY
ASSURANCE
OPERATIONS
MAINTENANCE
OPERATIONS
Maintenance
Management
(10.0)
Dennis Brandl & Peter Owen
Product
Shipping Admin
(9.0)
PRODUCTION
OPERATIONS
INVENTORY
OPERATIONS
Procurement
(5.0)
Product Cost
Accounting
(8.0)
Quality
Assurance
(6.0)
Marketing
& Sales
Research
Development
and Engineering
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ISA 95.03 Manufacturing Operations
Functions
Product
definition
Production
schedule
Production
capability
Production
performance
Detailed
production
scheduling
Production
resource
management
Production
tracking
Production
dispatching
Analysis
Production
data
collection
Product
definition
management
Production
execution
Equipment and Process
Specific Production Rules
Operational
Commands
Operational
Responses
Equipment and Process
Specific Data
Level 2 Process Control
Dennis Brandl & Peter Owen
21
Other Enterprise Activities in
Manufacturing Operations
• Production, Maintenance, Inventory, Quality
• Management of information, compliance, security,
documentation, and configurations
Level 4
Level 3
Inventory
Operations
Maintenance
Operations
Production
Operations
Management
of Information
Quality
Operations
Management
of Configuration
Management
of Security
Management
of Documentation
Management
of Compliance
Activity detailed
Level 2
Activity not detailed
Activity outside scope
Dennis Brandl & Peter Owen
22
Implementations
• Nestle
– Project to use the XML schemas for schedule
exchange
• Arla Foods
– Project to use XML for standard interfaces to
multiple ERP systems and MES systems
• Empersas Polar
– Project to use XML schemas for schedule
exchange
• Eli Lilly
– Projects to use ISA 95 models for manufacturing
operations management architecture
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Building Collaborative Manufacturing
Systems
• Process Used to Develop Solution
Architectures
–
–
–
–
–
–
Conceptual Topology
Functional Areas
Standards and Guidelines
Standard Applications
Logical Architecture Design
Physical Architecture Design
Dennis Brandl & Peter Owen
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ISA 95 Control Hierarchy Levels
Level 4
Level 3
Level 2
Level 1
Level 0
Dennis Brandl & Peter Owen
Business Logistics
Plant Production Scheduling, Shipping,
Receiving, Inventory, etc
Manufacturing
Operations Management
Dispatching, Detailed Production
Scheduling, Production Tracking, ...
Batch
Production
Control
Continuous
Production
Control
ISA – IEC/ISO
Interface
Standards
ISA
Functional
Model
IEC, OPC, &
OMAC
Interface
Standards
Discrete
Production
Control
The production processes
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Conceptual Topology – IT View
• IT View of the ISA-95 Levels and relationship to
systems and networks
• Levels 1-2
– Control the process and provide visibility to the process
– Electronic records are not embedded in the control layers
(Level 1-2)
– Usually some specialized hardware and possibly networks
• Level 3
– Maintenance of production information is centralized to
provide greater control and availability of the records
– Electronic records are managed and controlled through
Level 3 systems with audit trail, access control, backup, and
ERP connectivity
– Usually standard hardware and networks
Dennis Brandl & Peter Owen
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Conceptual Topology – IT View
ERP, APO,
Logistics Systems
Level 4
Business Process Information Network
MES, LIMS, WMS,
CMM Systems
Level 3
Operations Information Networks
Level 2
HMI, SCADA,
Batch Systems
Automation Networks
PLC, DCS,
Packaged Systems
Discrete & Process Device Communication Networks
Level 1
Dennis Brandl & Peter Owen
I/O, Devices,
Sensors
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Functional Areas
• Use the ISA 95 and ISA 88 models of functions
• Map the functions to system areas and networks
• Use the ISA 95 rules for determining what is in Level
3 (vs Level 4)
–
–
–
–
The function is critical to plant safety
The function is critical to product quality
The function is critical to plant reliability
The function is critical to maintaining regulatory compliance.
• Includes such factors as safety, cGMP, and environmental
compliance
• Maintaining FDA, EPA, USDA, OSHA, TÜV, EU, EMEA, and
other agency compliance
Dennis Brandl & Peter Owen
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Business Process Information Network
Production Dispatching
Production Execution Configuration Management
Production Analysis
Operations Information Networks
Level 2
Alarm Management
Operator Visibility
Operator Control
Supervisory Control
Equipment Information Collection
Recipe Control
Automation Networks
On/Off Control
Continuous Control
Programmed Control
Phase Control
Interlock & Safety Control
Discrete & Process Device Communication Networks
Level 1
Sense Events
Dennis Brandl & Peter Owen
Manipulate Equipment
Networking
Product Definition Management
Sense Process
Networking
Level 3
Production Tracking
Resource Management
Networking
Detailed Scheduling
Networking
Functional Areas – From ISA 95 & 88
Manipulate Process
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Logical Architecture
• Maps functional areas and data locations
– Independent of technology
• Defines the different layers of the architecture in
terms of data and control
– These are mapped to physical networks, servers, and
applications in the physical architecture
• Defines what functions are to be performed at each
level, and what data is to be maintained at each level
– To result in maintainable and robust systems
– To provide a way to manage the life cycle of the production
systems
– Provides the structure required to grow and modify the
system without compromising any of the previous
advantages
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Centralized
Servers
Desktop
Logical Architecture – IT View
Reports and
Analysis
Reporting HMI Engineering Tools
Investigations, Trends, …
Level 3
Diagnostics, analysis, …
Business Information Network
Fault tolerant
Permanent Database
Operations Control
Site Data Storage ERP Connection
Area Data Storage
MES
Operations Information Network
Production Areas
Operator Control
Batch Execution
Real-time Data and
Buffering
Real-time
Control and Data
Collection
Supervisory HMI Recipe Execution
Data Acquisition
Automation Network
Controllers Packaged Equipment
Sensors/Actuators
Process/Equipment
Dennis Brandl & Peter Owen
Level 2
Device Connection & /Networks
Level 1
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A Physical Architecture
• Defines the IT infrastructure and applications
–
–
–
–
Defines networks and network connections
Defines locations of applications
Defines locations of servers
Defines the mapping of applications to servers
• Physical architecture depends on the solution
set used:
–
–
–
–
Vendor capabilities
Networks
Security and network management
…
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One Instance Per Site
DataBase
Servers
Ethernet
Historian
Reporter
Network
Management
Router
Level 3
Domain Ctrl
DNS
VLAN
Switch
2 way Firewall
VLAN
Switch
Configuration
Server
Eng Tools
Diag Tools
High Alarm
Low Alarm
Comm. Err.
MES
Server
Domain Ctrl
DNS
Non operations tools
and views into data
Ethernet
HMI Server
Historian
Collection
Gateway
OPC
Ethernet
Network
Management
Router
Site
Information
Network
ERP
Connection
Ethernet
Area Operations Information Networks
Network
Management
Router
XML
Physical Architecture – IT View
PLC
High Alarm
Low Alarm
Comm. Err.
HMI
Viewer
Batch
Execution
WMS
Execution
One Instance Per
Process Cell
Automation Networks
DCS
Embedded PC
Packaged Equip
Device Networks
Dennis Brandl & Peter Owen
Level 2
Level 1
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Conclusions
• Linked execution systems deliver results!
– Reduced direct costs; increased productivity
– Improved traceability; reduced “witch hunt” expense
– Near-theoretical cycle times: customer responsiveness,
reduced WIP inventory
– Greater agility: smaller lot sizes, more premium products in
the mix, happier customers, happier shareholders!
• S95 defines the currency for manufacturing object
and information exchange
– Faster project implementation cycles
– Flexibility to integrate and realign as corporate structures
change
Dennis Brandl & Peter Owen
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Status
• ISA95.00.01 & ISA.95.00.02 available
• IEC/ISO 62264-1 available from IEC & ISO
• ISA 95.00.03 in draft
– Still under development in the committee
• World Batch Forum
– Developed XML Schemas for the exchanged
information
• Vendors
– Many currently using ISA-95 models in
development and current products
• Users
– Specifying ISA-95 in their RFPs
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