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System 800xA
Arto Lind ISA-95/S88 Standards
Batch
Information Management
MES
functionality
13 mars 2007
ABB Group - 1 -
Jun 5, 2017
ISA-95 Perspective on Manufacturing
Level 4
Business Planning Timeframe: Months,
Business & Supply Chain weeks, days, shifts
Process Mgmt
transactions
ISA-95.01/02 Production Production Production Production
Manufacturing Facility
Level 0, 1, 2
L
F
F F
L
ABB Group - 2 -
L P
T
T
F L F
L
Jun 5, 2017
ABB Coverage
ISA S95 Standard Scope
ENTERPRISE
Detailed Production
Production Resource
MES
Product Analysis
Product tracking
Production Data
management
Maintenance
Product Data
Management
CPM Layer*
Scheduling
Management
SCADA
Production
collection
analysis
(if existing)
DCS / PLC
To Define:
Activities of manufacturing Operations Management
Terminology and a consistent set of concepts and
models for defining manufacturing operation
management activities
Interactions between activities
Data that flows among these activities
ABB Group - 6 -
Jun 5, 2017
Production Operations
Product Production Production Production
definition capability schedule performance
Detailed
production
scheduling
Production
Production
resource
tracking
management
Production
Production
Performance
dispatching
analysis
Product Production
definition data
management collection
Production
execution
Product Historical
Process
Definition Data
Analysis
Management Management
800xA Production
Production Execution Production
Management Analysis
Monitoring Control
Manual 800xA
Jun 5, 2017
Operations Operations
System 800xA
Production
Management What is 800xA Batch Management?
Batch Management is a comprehensive batch
automation solution for:
Configuring recipes and
procedures
Configuring batch equipment
Scheduling, monitoring and
controlling batches and
campaigns
Automatic arbitration of
resources between batches at
runtime
Collecting and storing batch
historical information
ABB Group - 9 -
Jun 5, 2017
ISA S88.01 Batch Standard
Equipment Hierarchy Procedure Hierarchy
Area Procedure
at
Process Cell
o w
Unit Procedure
W h Unit
H
Operation
Equipment
Phase
Module
ABB Group - 10 -
Jun 5, 2017
ISA S88 Procedure Hierarchy
Production strategy organized by levels
Procedure
Procedural elements can be used in
Unit
multiple procedures
Procedure An element within a Procedure Function
Chart (PFC) may represent another
Operation nested Procedure
Initialize
Unit ready
Phase Inert
Pressure
Procedure Function
Chart (PFC) Editor
provides a
graphical workflow
of operations and
procedures
ABB Group - 12 -
800xA to external
Business System
applications Business System
System 800xA
Batch Management
Examples of actions
supported Production
Request(s) Production
Scheduling a batch Response(s)
Operations
Production Production
Production Production
Orders Reports
Orders Reports
Control
Recipes
Phases Batch
Information
Management
Management
Server
PDL
Control Procedures
Operations
Numeric Trend Data
Control & System Events
Operator Actions
ABB Group - 17 -
DDRIVE
(123)
Control &
I/O
RCM(62) AO (29)
Jun 5, 2017
(68)
AO (29)
(68)
Engineering Production
Common Equipment Model of System 800xA
Object Type Functional Equipment Procedure
Structure Structure Structure Structure
Master
Recipes
ABB Group - 18 -
Equipment
Groups
Jun 5, 2017
Instances of
Unit Types Physical Equipment
AC800M Controller Integration
Equipment Batch
Overview Overview
Procedure Process
Function Graphic
Chart
ABB Group - 20 -
Jun 5, 2017
System 800xA
Production
Management
Flexible Recipe Management
Improves production yields,
Reusable recipe building minimizes scrap, and improves
blocks follow S88 batch overall production profitability.
control standard
Exception procedures
provide recipe-driven error
handling capability,
breakpoints and block skip
points
View current status of recipe
procedures and associated
standard operating procedure
Supports on-line changes to
control recipe without
suspending the batch Procedure Function Chart Standard Operating
Procedure
ABB Group - 21 -
Jun 5, 2017
Full Support for FDA 21 CFR Part 11
System 800xA provides features across the entire
system that facilitate validation
Security authorization & access control
Configuration change management
Versioning
Synchronization between engineering &
production systems
Batch will provide on-line versions for
procedures
Audit trail logging by audit event type
E-signatures & signature/record linking
Record archiving & retrieval
Reporting - printed copy of records for
inspection
System checks - device checks and permitted
sequences
ABB Group - 22 -
Product Historical
Process
Definition Data
Analysis
Management Management
800xA Production
Production Execution Production
Management Analysis
Monitoring Control
Manual 800xA
Jun 5, 2017
Operations Operations
Information
Management Production Performance Analyses - Information Management
Information
availability
External
Production
Data
Application (ERP, MES etc..)
Archiving Engine
Integration
Control Room
Data
Information Manager
Enterprise Edition
Server
ABB Group - 26 -
Jun 5, 2017
Information
Management Seamless handling of historical data
Operator Workplace/Desktop Display
Messages Real-time and
in the History data
Seamless view
800xA System in History Server of all data
System
alarms/events 50k messages 50k messages 12 million messages
Audit Trail
alarms/events 1 sec /1 week - 1sec / 10 years
Trend logs
in Connectivity
Server
DeskTop Trend
Trend Control
Tag Ticker
ABB Group - 32 -
Jun 5, 2017
Softpoints & Calculation exempel
Transform data into
User-defined data points actionable information
Calculation
aspect
Softpoint
object
Softpoint Calculation
signals script
ABB Group - 33 -
Jun 5, 2017
Flexible
Reports Flexible Report generation & distribution
Report generation
Printer
Email
Historical archiving
Lolal- or network-disc
ABB Group - 34 -
Jun 5, 2017
Security
Secure Data Security in Pharmaceutical Industry
are stored
Jun 5, 2017
Complete electronic
batch records
ISA S95.03d Production Control Functions
Product Historical
Process
Definition Data
Analysis
Management Management
800xA Production
Production Execution Production
Management Analysis
Monitoring Control
Manual 800xA
Jun 5, 2017
Operations Operations
Introduction
ECS Framework closes information gap between Business processes
and the Manufacturing processes (machines, control systems).
ECS
ABB Group - 38 -
Jun 5, 2017
Functionality
BRIDGE BETWEEN PLANT FLOOR CONTROL
SYSTEMS AND ENTERPRISE BUSINESS SYSTEMS
ENHANCEMENT OF RESPONSIVENESS TO
BUSINESS DECISIONS
IMPROVEMENT
Jun 5, 2017
Levels
Business
System
800xA
Core
800M Controller
ABB Group - 41 -
Jun 5, 2017
Manufacturing Process Model
Based on S95 standard
Includes
Process data
Process workflow definition
Representation of the process model is saved as an
XML file
S95 Objects
ABB Group - 42 -
Jun 5, 2017
Manufacturing Process Execution
Manufacturing Process Modeling tool (S95)
Executable
Code
Business
Business
System1
Business
System1
Systems
(GUI)
Jun 5, 2017
MES
ECS- Enterprise Connection Solution
Configurable connectivity to various business systems (e.g. SAP) or
any ERP from SSA Global including BAAN
Tracking & Traceability, Reports, Database connector
Based on
- 95
Case: SAP PPPI ABB 800xA Batch Management integration
Download of the SAP control recipe to 800xA System with all parameters required
for batch production
800xA system updates SAP system with production status throughout the batch
execution
At the end of batch production 800xA system reports to SAP all production
relevant data (consumption per ingredient, produced material quantity, Phase
confirmation and report of used machine and total production time etc.)
Batch production data
(consumption, confirmation, quantity produced)
BAPIs, RFCs
SAP Control
Recipe
IM Batch
Jun 5, 2017
Control System
Development of the ABB-SAP Joint Solution
ABB-SAP ABB-SAP Task force Joint solution Joint solution
Co-operation Task force results with development ready to deploy
initiated Pulp & Paper recommendations
2004-04 2004-04-12 2004-12 2005 2006
Sapphire Paris
Custom
Run Scheduling Schedule
Evt. stock Optimization
transfer Roll
PTP
ers
Machine Simplex Warehouse
Winder
IT and Organizational Pain Points
Optimization
Customer
Sheeter
Detail Scheduling
In operation since
Industrial IT Production Planning Retrim Pulp
Simplex
ABB Oy / SAP AG 2004, SAP ABB Task Force / 37
Reallocation Sheeter
Re- Pallet
2004 in ABBs
Coater SC
Scheduling ABB
ABB Production Merger / Divestment reeler Wrap
SAP
Patterns Patterns
plant in Dalmine, another company / CutSize (Standard sizes)
ABB Oy / SAP AG 2004, SAP ABB Task Force / 39
Paper Machine Reels Reel Reels Rolls Warehousing Any RDBMS Sheets
Run
Winder Rewinder Wrapline
Copyright year ABB - 34 -
Warehouse management:
Jun 5, 2017
Mill warehouses 24 x 365, often also integrated with the automation systems
ABB Oy / SAP AG 2004, SAP ABB Task Force / 48
Database
(ramp controls, wraplines, etc.). From this point of view, makes sense to be in the
mill system. But what is the sufficient level of integration to SAP for things like
Copyright year ABB - 3 -
800xA
ABB and 3rd party control systems and historians
ABB CPM
Devices ABB Historian ABB Controls 3rd party 3rd party
Historian controls
Connecting to SAP View from 800xA
products