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Manufacturing Operations Management

Manufacturing Operations Management. Dennis Brandl Peter Owen BR&L Consulting Eli Lilly & Co. 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

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Manufacturing Operations Management

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  1. Manufacturing Operations Management Dennis Brandl Peter Owen BR&L Consulting Eli Lilly & Co

  2. 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 also include 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 • The Manufacturing Operations Management models are currently being used in the development of multiple new manufacturing facilities

  3. 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

  4. 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

  5. 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 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 Different Points of View

  6. Philosophical Orientation • Enterprise Management systems: • How much is my stuff worth? • Manufacturing Opearations Systems: • Where is my stuff?

  7. 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”

  8. ISA95.01 Levels Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Interface addressed in the ISA 95.01 and ISA 95.02 standard Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Area addressed in the ISA 95.03 standard Levels 2,1,0 Batch Control Continuous Control Discrete Control

  9. ISA95.01 Levels Business Logistics Management (ERP) Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Interface addressed in the ISA 95.01 and ISA 95.02 standard Manufacturing Operations Management (MES, LIMS, AM, …) Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ... Area addressed in the ISA 95.03 standard Levels 2,1,0 Batch Control Continuous Control Discrete Control

  10. ISA 95 Part 1 and Part 2 Exchanged Information Information that crosses the boundary between business systems and manufacturing systems

  11. Exchanged Information Categories Enterprise Information Plant Production Scheduling, Operational Management, etc Production Schedule (What to make and use) Production Performance (What was made and used) Production Capability Information (What is available for use) Product Definition Information (How to make a product) Manufacturing Control Information Area Supervision, Production Planning, Reliability, Assurance, etc

  12. 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

  13. People Process Segments Equipment Materials Four Resource Object Models Personnel resources managed for production Equipment resources managed for production Material resources managed for production Business view of production processes

  14. Product Time Capability/Capacity Product Definitions Production Schedule Production Performance Capability, Product, Schedule, and Performance Information What is available for use for production What is needed to make a product What to make and resources to use What was made and resources actually used

  15. People Segments Equipment Materials Per location (Site, Area, …) Per week, day, shift, order, … Production Schedule Production Schedule • 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,…) • Production Schedule • Production Request • Segment Request • Expected Produced Material • Expected Consumed Material • Expected Personnel • Expected Equipment • Production Parameters • …

  16. People Segments Equipment Materials Production Performance Production Performance • Production Performance • Production Response • Segment Response • Produced Material Actual • Consumed Material Actual • Personnel Actual • Equipment Actual • Production Data • … • What was made • What material was actually produced • What materials were actually consumed • Equipment used • Personnel used • Production data (e.g. Purity, density,…) Per location (Site, Area, …) Per shift, hour, end of batch, …

  17. 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 • One schema for each object model • Formal way to exchange information • www.wbf.org

  18. 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>

  19. ISA95 Part 3 Activity Models of Manufacturing Operations In Development Expected Release 2004

  20. Order Processing (1.0) Product Cost Accounting (8.0) Product Shipping Admin (9.0) Production Scheduling (2.0) PRODUCTION OPERATIONS INVENTORY OPERATIONS Material and Energy Control (4.0) Production Control (3.0) Product Inventory Control (7.0) INVENTORY OPERATIONS QUALITY ASSURANCE OPERATIONS Procurement (5.0) MAINTENANCE OPERATIONS Quality Assurance (6.0) Marketing & Sales Maintenance Management (10.0) ResearchDevelopment and Engineering

  21. Product definition Production capability Production schedule Production performance Detailed production scheduling Production tracking Production resource management Analysis Production dispatching 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 ISA 95.03 Manufacturing Operations Functions

  22. Activity detailed Activity not detailed Level 4 Activity outside scope Inventory Operations Management of Information Management of Configuration Level 3 Maintenance Operations Quality Operations Management of Security Production Operations Management of Documentation Management of Compliance Level 2 Other Enterprise Activities in Manufacturing Operations • Some actives are not specific to manufacturing • ISA-95.03 lists references to standards in these areas Major Activities Within Manufacturing Operations

  23. 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

  24. 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

  25. ISA 95 Control Hierarchy Levels Level 4 Business Logistics Plant Production Scheduling, Shipping, Receiving, Inventory, etc ISA – IEC/ISO Interface Standards ISA Functional Model Level 3 Manufacturing Operations Management Dispatching, Detailed Production Scheduling, Production Tracking, ... IEC, OPC, & OMAC Interface Standards Level 2 Batch Production Control Continuous Production Control Discrete Production Control Level 1 Level 0 The production processes

  26. 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

  27. Conceptual Topology – IT View Level 4 ERP, APO, Logistics Systems Business Process Information Network Level 3 MES, LIMS, WMS, CMM Systems Operations Information Network Level 2 HMI, SCADA, Batch Systems Automation Network PLC, DCS, Packaged Systems Level 1 Discrete & Process Device Communication Networks I/O, Devices, Sensors

  28. 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 maintaining regulatory compliance. • Includes such factors as safety, cGMP, and environmental compliance • The function is critical to plant safety • The function is critical to product quality • The function is critical to plant reliability

  29. Functional Areas – From ISA 95 & 88 Networking Business Process Information Network Level 3 Detailed Scheduling Resource Management Production Tracking Product Definition Management Production Dispatching Configuration Management Production Analysis Production Execution Networking Operations Information Network Level 2 Recipe Control Supervisory Control Alarm Management Operator Control Operator Visibility Equipment Information Collection Networking Automation Network Phase Control On/Off Control Continuous Control Programmed Control Interlock & Safety Control Level 1 Networking Discrete & Process Device Communication Networks Sense Process Sense Events Manipulate Equipment Manipulate Process

  30. 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

  31. Area Data Storage Logical Architecture – IT View Level 3 Reporting HMI Engineering Tools Reports and Analysis Desktop Investigations, Trends, … Diagnostics, analysis, … Business Information Network Site Data Storage ERP Connection Fault tolerant Centralized Servers Permanent Database MES Operations Control Level 2 Supervisory HMI Recipe Execution Operator Control Batch Execution Operations Information Network Real-time Data and Buffering Data Acquisition Production Areas Automation Network Real-time Control and Data Collection Controller Packaged Equipment Level 1 Device Connection & /Networks Sensors/Actuators Process/Equipment

  32. 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 • …

  33. DataBase Servers Historian Reporter Eng Tools High Alarm Low Alarm Comm. Err. High Alarm Low Alarm Comm. Err. Domain Ctrl ERP Connection Diag Tools DNS Configuration Server Domain Ctrl MES Server DNS Batch Execution HMI Server Historian Collection Gateway OPC Physical Architecture – IT View XML Level 3 Site Information Network VLAN Switch 2 way Firewall Network Management Router VLAN Switch Non operations tools and views into data Area Operations Information Network Level 2 Ethernet Network Management Router HMI Viewer One Instance Per Process Cell Automation Network Ethernet Level 1 Network Management Router PLC DCS Embedded PC Packaged Equip

  34. 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

  35. 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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