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An ISA95 Overview: Workflow and System Modeling for 21st Century Manufacturing Flexibility
Charlie Gifford Solutions Architect-Lean Performance Mgt. Global Professional Services Business Office (208) 788-5434 Fax: (208) 788-5690 Cell (208) 309-0990 Charlie.Gifford@ge.com
Seminar Overview
Goal of the ISA95 Effort Collaborative Production Management (CPM) Business Drivers ISA95 Direction and Scope of Plant Model Agreement of Control Responsibility Object Model Four categories of resources Four categories of information Part 3: Manufacturing Operations Model Question: What does this mean for actual project implementation? XML - schemas ERP-Proficy connector ISA95 Status
Goals
Understand the market drivers for ISA95 Understand the two points of view for supply chain optimization ISA95 Value and Direction Agreement of Control Responsibility Understand Object Model Proficy is ISA95 Compliant Understand ISA95 Business Value
To reduce inventory or meet your companys Make-To-Order strategy, you need to run very short schedules (multiple per day) and very fast end of production responses (immediate)!
PS: Dont increase inventory or staff
2004 GE Fanuc Automation All rights reserved.
Business Logistics
Manufacturing Operations
Business Logistics
Manufacturing Operations
ETO
MTO
MTS
The 9 combinations (or hybrids) of Production Type and Work Order Management each have a different set of business rules processes in their supply chain, enterprise and production base
2004 GE Fanuc Automation All rights reserved.
The rate: the system generates money through sales (I) Inventory (and investments) : The money the system invests in things it intends to sell (all saleable resources: material, equipment) (OE) Operational Expenses : The money the system spends to transform Inventory into Throughput
$$$ Throughput Money coming in
$$$ Inventory
Money tied up inside
Return
Return
Supplier
Internal or External
Return
Your Company
Return
Customer
Internal or External
Corporate approach set by optimization view Supply Chain vs. Plant Optimization: 60-80% Liquid Assets are in Supply Chain 60-80% Tangible Assets in your Plants
2004 GE Fanuc Automation All rights reserved.
Scope
ENTERPRISE
SITE
ISA95 Standard
AREA
AREA
AREA
Scope
ENTERPRISE
95.03
AREA AREA AREA
ISA95 Standard
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 Area addressed in the ISA 95.03 standard
Levels 2,1,0
Batch Control Continuous Control Discrete Control
From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org
ISA95.01 Levels
Level 4
Interface addressed in the ISA 95.01 and ISA 95.02 standard Area addressed in the ISA 95.03 standard
Batch Control
Continuous Control
Discrete Control
Information must efficiently and effectively cross the boundary between business and manufacturing systems
Part 2 defines:
Part 3 defines:
Information Definitions
Categories of Information
2004 GE Fanuc Automation All rights reserved.
Procurement (5.0)
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)
Why ?
Where is the responsibility ? Who has the responsibility ? Where are firewalls needed (policy and technology) ?
Production
Production capability Production schedule Production performance Quality definitions Quality test capability Detailed production scheduling
Quality
Quality test request Quality test response Inventory definitions Detailed quality test scheduling
Inventory
Inventory capability Inventory request Inventory response Detailed inventory scheduling
T R
Maintenance resource management
Maintenance tracking
Production tracking
Inventory tracking
Maintenance dispatching
Maintenance analysis
Production dispatching
Inventory dispatching
Inventory analysis
Maintenance execution
Production execution
Inventory execution
Level 2
Procurement (5.0)
From ANSI/ISA-95.00.01-1995 Copyright ISA 2000. Used with permission. www.isa.org 2004 GE Fanuc Automation All rights reserved.
Materials
Qualification Test
AREA
PRODUCTION UNIT
Lower level Lower level Lower level Lower level equipment used equipment used equipment used equipment used in continuous in repetitive or in inventory in batch operations operations discrete operations operations
Lot HCL-50-100019
pH Density
Color Purity
QA Test Results
pH 1.0
Process Segments
The business view of production
Raw Materials Finished Products
Pharmaceutical Manufacturing
(3 Segments) Make Active Ingredient Make Pills Package Doses
Know throughput, Know throughput, resources and time to resources and time to make Active Ingredient make Pills
Capability/Capacity
Time
Product Definitions
Time
Capabilities
Equipment
Materials
What is available - Currently - In the future - Per resource - Per segment of production - What is available - What is unattainable - What is committed
Segments
2004 GE Fanuc Automation All rights reserved.
Capacity
Time
Current Capacities
2004 GE Fanuc Automation All rights reserved.
Product Definition
Shared information about each product between Level 3 and 4
References manufacturing instructions
> For Continuous may be flow sheets > For Batch may be site or master recipes > For Discrete may be setup or assembly instructions
Product Definition
References the Bill of Materials References the Bill of Resources Defines resources required per segment
Equipment Personnel Material
Product Definition
Product Segments
Material System
Bill Of Materials e.g. 10 Speed Bicycle
f ll O als i Bi er at M
Paint
Color
Manufacturing System
2004 GE Fanuc Automation All rights reserved.
Manufacturing Bill Frame : 1 Wheels : 2 Chain : 1 Seat : 1 Handlebars :1 Brake Pads : 4 ...
Production Schedule
People
Production Schedule What to make Production Request - Priority and/or dates Segment Request Expected Produced - What to use: -Materials Material -Equipment Expected Consumed -personnel Material - Production parameters Expected Personnel (e.g. Color, Options,) Expected Equipment Production Parameters
Equipment
Materials
Production Schedule
Segments
2004 GE Fanuc Automation All rights reserved.
Production Performance
People
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,)
Equipment
Materials
Segments
Production Performance
2004 GE Fanuc Automation All rights reserved.
PRODUCTION OPERATIONS
Production Control (3.0)
INVENTORY OPERATIONS
Procurement (5.0)
Production performance
(Per Workcenter or Workcenter element, Per produced item, Per Time Very Short Time Horizon)
Level 3
Management of Documentation
Level 2
B2MML: Schemas
Common Schema Equipment Schema Material Schema Personnel Schema Process Segment Schema Product Definition Production Capability Production Performance Production Schedule Maintenance Schema
2004 GE Fanuc Automation All rights reserved.
Why XML ?
Openness Simplicity Self-describing Interoperability Structure Extensibility Platform independency X-Path Query Language Self-documenting Fully Extensible
2004 GE Fanuc Automation All rights reserved.
S95 Connector
Status
ISA95.00.01 & ISA.95.00.02 available IEC/ISO 62264-1 available from IEC & ISO ISA 95.00.03 /.04/.05 in draft World Batch Forum Vendors Users
Still under development in the committee Developed XML Schemas for the exchanged information Many currently using ISA-95 models in development and current products Specifying ISA-95 in their RFPs