Industrial IT

System 800xA
Arto Lind ISA-95/S88 Standards
Batch
Information Management
MES
functionality

13 mars 2007
ABB Group - 1 -
23-Oct-17
 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

Definition Capability Plan Information ISA-95.05

Definition
Functionality
Level 3
Production Manufacturing Operations Timeframe: Day,
Management
Transactions Management Shift, Hour, Minutes,
Seconds
ISA-95.03/04 Functionality
Real-Time Control & Continuous Batch Discrete
Events
Sensors, Actuators and Logical Devices

Level 0, 1, 2
ABB Group - 2 -
23-Oct-17

ABB Coverage
 ISA S95 Standard Scope

ENTERPRISE

ISA S88 95.01 & .02

Standard ISA95
SITE
Standard
95.03
AREA AREA AREA
ABB Group - 3 -

CONTINUOUS BATCH DISCRETE

PRODUCTION PROCESS PRODUCTION
23-Oct-17

UNIT CELL LINE

 Enterprise and Control Layers are Merging

1985 1995 2005

Business Planning & Logistics
Production Planning
ERP Enterprise Layer Extended ERP
Manufacturing Operations
Execution and Control

Detailed Production

Production Resource
MES

Product Analysis

Product tracking
Production Data

management
Maintenance
Product Data
Management

Management
Scheduling
SCADA CPM Layer*

Production
collection

analysis
(if existing)

DCS / PLC

Plant Instrumentation and Control Layer Extended Manufacturing

Controls
ABB Group - 4 -
23-Oct-17
 Platform for Control and CPM/MES
One common platform for all manufacturing functions
Utilize modular 800xA software functions as required
ERP ISA-95 LIMS/DMS/etc
Specific Adaptors Web Services Traditional Interface

Enterprise Connectivity Solutions (ECS)

Real-Time Asset
Manufacturing Information Batch Enterprise
Production
Management Management Management Optimization Connectivity
Intelligence
Solutions
(ECS)

Common Operations, Engineering, & Data Management

ABB Group - 5 -

- - - - - - - - - - - - - - - - Real-time Data Sources- - - - - - - - - - - - -

23-Oct-17

Blending Granulation Tablet Coating Other OPC

 Scope of ISA 95 Part 3

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 -
23-Oct-17
 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

Equipment and process Operational Operational Equipment and process

specific production rules commands responses specific data
ABB Group - 7 -

Production level 1-2 functions

23-Oct-17
 ISA S95.03d Production Control Functions

Product Production Production Production Supply Chain

Definitions Capability Schedule Performance Integration
ECS Enterprise
Connectivity Solution
Detailed
Production
Scheduling
800xA
Information
Resource Production Management
Management Tracking

Production (QA) Product

Dispatching Analysis

Product Historical
Process
Definition Data
Analysis
Management Management
800xA
Production
Production Execution Production
Management Analysis
-Batch Process Automated
ABB Group - 8 -

Monitoring Control
Manual 800xA
Operations
23-Oct-17

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 -
23-Oct-17
 ISA S88.01 Batch Standard
Equipment Hierarchy Procedure Hierarchy

Area Procedure

Process Cell Unit Procedure

Unit Operation

Equipment
Phase
Module
ABB Group - 10 -
23-Oct-17
 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

Press > target

An element within a PFC may
Vent
launch and supervise sequential
ABB Group - 11 -

logic in process controller

23-Oct-17
 System 800xA
Production
Management Product Definition Management

Procedure Function
Chart (PFC) Editor
provides a
graphical workflow
of operations and
procedures
ABB Group - 12 -

Single master recipe for automated

23-Oct-17

and manual production workflows

 System 800xA
Batch Management Integrated Equipment Configuration

Supports network, multi-path

and single path equipment
configurations
Integrates with the common
object model of 800xA System
Reserves and allocates
equipment and other resources
at run-time based on priority of
each batch
Provides views and control of
equipment status (Available,
Busy, Reserved, etc.), Batch ID,
equipment attributes, and
reservation queue Single, unified plant object model
reduces engineering costs.
ABB Group - 13 -
23-Oct-17
 System 800xA
Production
Management Production Resource Management
View equipment status (Available, Busy, Reserved, etc.)
View Batch ID
View and change equipment attributes
View and manipulate reservation queue
ABB Group - 14 -
23-Oct-17
 System 800xA
Production
Management Production Scheduling / Dispatching
Schedule control recipes
based on master recipes and
batch-specific formulation
data
Supports multiple execution
of batches within a campaign
Select equipment at
schedule time or dynamically
at run-time
View batch status,
parameters, history options
and messages
Easily navigate procedure
hierarchy of all active Simple utilities for Recipe, Resource,
batches and Production Management
ABB Group - 15 -

One-button duplicate feature provide full functionality.

23-Oct-17
 System 800xA
Production
Management Production Schedule Interface
Create Execute Upload
Process Process Process
Enables interfaces from Order Order Order

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)

Retrieving status Schedule Production

Batches Records
information
Changing batch state * *
and parameters * Message broker /
Transaction Mgr
Retrieving batch Manufacturing
Management
history variables
Provides complete access to information
ABB Group - 16 -

required for business system integration.

23-Oct-17
 System 800xA
Production
Management Functional Structure and Components
Recipes Scheduler ERP/MES Applications

Operations
Production Production
Orders Reports

Control
Recipes
Phases Batch
Information
Management
Management
Server
PDL
Control Procedures
Batch Events
Plant Explorer Operator Comments

Operations Numeric Trend Data

Control & System Events
Operator Actions
ABB Group - 17 -

DDRIVE
(123)
Control &
RCM AO (29)
(62)
(68) I/O
23-Oct-17

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
23-Oct-17

Instances of
Unit Types Physical Equipment
 AC800M Controller Integration

Equipment Procedure Template

(EPT) Phase Logic Interface to
Produce IT Batch
Separate code blocks for S88 states
(e.g. running, holding, aborting, etc.)
ABB Group - 19 -
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 System 800xA
Production
Management Operator Workplace with Batch

Equipment Batch
Overview Overview

Procedure Process
Function Graphic
Chart
ABB Group - 20 -
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 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 Procedure Function Chart Standard Operating
suspending the batch Procedure
ABB Group - 21 -
23-Oct-17
 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
ABB Group - 22 -

permitted sequences
Native language support
23-Oct-17

SOPs for Part 11 and cGMP

 Batch Production Data Management

Logs batches according to

procedure hierarchy
Displays and analyzes trends
of same or different batches
Supports LAB data entry
Prints reports using third party
report builder
Archives data and reports
Provides access to other
applications through SQL and
programmed APIs The hierarchical data storage greatly
facilitates batch to batch analysis quickly
ABB Group - 23 -

providing useful information for making

intelligent business decisions.
23-Oct-17
 ISA S95.03d Production Control Functions

Product Production Production Production Supply Chain

Definitions Capability Schedule Performance Integration
ECS Enterprise
Connectivity Solution
Detailed
Production
Scheduling
800xA
Information
Resource Production Management
Management Tracking

Production (QA) Product

Dispatching Analysis

Product Historical
Process
Definition Data
Analysis
Management Management
800xA
Production
Production Execution Production
Management Analysis
-Batch Process Automated
ABB Group - 24 -

Monitoring Control
Manual 800xA
Operations
23-Oct-17

Operations
 Information
Management Production Performance Analyses - Information Management

Desktop, Reporting & Analysis

Information
availability
External
Production
Data
Archiving Engine Application (ERP, MES etc..)
Integration
Control Room
Data

Process Data Alarm & Event Data Production Data

ABB Group - 25 -
23-Oct-17
 InformIT Information Manager Architecture

Information Manager
Enterprise Edition
Server
ABB Group - 26 -
23-Oct-17
 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

Process Historical storage Archive

alarms/events

Trend logs
in Connectivity
Server

OPC Data Access items: 40.000 items

1 sec /1 week
OPC update rate: > 0.1s (1s default)
ABB Group - 27 -

Primary logs/Con.Server: 5.000 logs

Primary logs/IM Hist.Server: 30.000 logs Control Network
Updated min log values: 30.000/min
23-Oct-17

Req. max buffer size: Con.Server: 3 months

Max buffer size: IM Hist.Server: 10 years
 Information
Management Production Data Log
Robust data structures
Correlation of batch history with continuous history
(highly configurable -- doesnt require custom code)
Batch to Batch comparisons
Pre-canned reports that can be used right out of the
box
B

Job Name: Production Polystyrene grade 4

Campaign Recipe Name: Polystyrene_A4

Batch Name: Batch 1

B a tc h 1 Start T ime: 9/29/95 14:05:00
End T ime: 9/29/95 22:07:25

Unit Procedure: Reaction

Unit Unitname: Reactor R-105
Proceedure 1 Start time: 9/29/95 14:30:20
End time: 9/29/95 18:23:03
Phasename: Heat
Operation start: 9/29/95 14:32:40
initial temp: 23.5 Deg. C
ABB Group - 28 -

target temp: 55.0 Deg. C

end: 9/29/95 16:35:12
B a tc h 2 final temp: 55.1 Deg. C
23-Oct-17
 Information
Management Presentation and Navigation

Seamless process and history data retrieval

Straightforward trend presentation
Process Portal Trend Display and Information Manager Display
Clients present common (short and long term) set of data
Plant Explorer navigation for Information Manager data
ABB Group - 29 -
23-Oct-17
 Information
Management Presentation and Navigation

Single, seamless interface for accessing and viewing all

data in the system
Maintain data in original control system format
Process alarms, system events, operator actions
Production data, process relationships
ABB Group - 30 -
23-Oct-17
 Information
Management Web Clients
ABB Group - 31 -
23-Oct-17
 Information
Management Presentation and Navigation

DeskTop Trend
Trend Control
Tag Ticker
ABB Group - 32 -
23-Oct-17
 Softpoints & Calculation exempel
Transform data into
User-defined data points actionable information

Calculation
aspect

Softpoint
object
Softpoint Calculation
signals script
ABB Group - 33 -
23-Oct-17
 Flexible
Reports Flexible Report generation & distribution

Microsoft Excel, Crystal

Report

Real time data, historical, lab

data, batch- and event-
information

Report generation
Printer
Email
Historical archiving
Lolal- or network-disc
ABB Group - 34 -
23-Oct-17
 Security
Secure Data Security in Pharmaceutical Industry

Secure historical data storage

Archival/retrieval from external
media
CD, DVD, Magneto Optical
Remote disk location
Direct read of archived tag
data
Archive based on production
event such as batch end
Distributed data storage
Secure report storage
Disk arrays
User access control
ABB Group - 35 -
23-Oct-17
 System 800xA
Information
Management Production Data Collection / Tracking
Camp1 Campaign Name: Intermediate_S7_2004AXH
Recipe Name: Int_S7_Std

Batch Name: Batch_1

Batch 1
Start Time: 9/12/04 14:05:00
End Time: 9/12/04 22:07:00

UP1 Unit Procedure: Reaction

Unitname: RE105
Start time: 9/12/04 14:30:20
End time: 9/12/04 18:23:03

OPN 1 Operation name: Heat

Start time: 9/12/04 14:32:10
End time: 9/12/04 17:32:40

Single common storage of

Batch 2 batch record
Data stored according to
batch recipe structure

All batch events, operator
actions, system events,
process alarms and events
ABB Group - 36 -

are stored
23-Oct-17

Complete electronic
batch records
 ISA S95.03d Production Control Functions

Product Production Production Production Supply Chain

Definitions Capability Schedule Performance Integration
ECS Enterprise
Connectivity Solution
Detailed
Production
Scheduling
800xA
Information
Resource Production Management
Management Tracking

Production (QA) Product

Dispatching Analysis

Product Historical
Process
Definition Data
Analysis
Management Management
800xA
Production
Production Execution Production
Management Analysis
-Batch Process Automated
ABB Group - 37 -

Monitoring Control
Manual 800xA
Operations
23-Oct-17

Operations
 Introduction
ECS Framework closes information gap between Business
processes and the Manufacturing processes (machines, control
systems).

ECS
ABB Group - 38 -
23-Oct-17
 Functionality
BRIDGE BETWEEN PLANT FLOOR CONTROL
SYSTEMS AND ENTERPRISE BUSINESS SYSTEMS

ENHANCEMENT OF RESPONSIVENESS TO
BUSINESS DECISIONS

MANUFACTURING VISIBILITY - EFFICIENCY

ISSUES, PRODUCTIVITY ISSUES, AND QUALITY
ECS =
ECS = ISSUES IN CONTEXT

PRODUCTION REALITY PLAN, RESPOND AND

CHANGE ON DEMAND; NO MORE GUESSING

QUALITY DATA MANAGEMENT - RECOGNISE

AND RESPOND TO QUALITY CHALLENGES
ABB Group - 39 -

EVOLUTIONARY APPROACH - CONTINUOUS

IMPROVEMENT
23-Oct-17
 Levels

Factory and domain specific

Applied Manufacturing Framework
deployments

Methodology and tools for modeling and

implementation of solutions for
Manufacturing Framework
different factories and manufacturing
domains.

Reusable software components, fully

integrated in 800xA Core Platform
IT Framework

800xA Core Platform

ABB Group - 40 -
23-Oct-17
 ECS Based Connectivity

ECS Makes Business Systems visible to the rest of the

800xA System as just another control equipment

Business
System

800xA
Core
800M Controller
ABB Group - 41 -
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 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 -
23-Oct-17
 Manufacturing Process Execution
Manufacturing Process Modeling tool (S95)

Executable
Code
Business
Business
System1
Business
System1
Systems

Manufacturing Process Model-based Devices

Database
Integration People
ABB Group - 43 -

(GUI)
23-Oct-17
 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

800xA 800xA SAP

ECS
ABB Group - 44 -

PP-PI
IM Batch
23-Oct-17

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

Initial industry: Pulp Detailed

& Paper analysis of production
Taskforceand business
results processes of various
and recommendations
Concrete development P&P to
presented
Taskforce Charter: industry segments management ABB CPM Connector for Pulp & Paper
17 workshop sessions, 8 months ABB ECS framework
Define appropriate customer segmentationAgreed(products, regions,)
to continue to concrete actions:
SAP Connectivity and Netweaver
Identify pain points of the different customer groups
Pilot customers certification
Linerboard Example

Determine where there are pain points which are significant

Integrated and refined
scenarios where we can Forecast or
Replenishment

find/have a combined solution Customer ATP

N
CTP Prod. Plan. Prod. Plan Planning
Order Entry Check Check Winder Paper Mach. Pulp

Evt. stock transfer ECS Overview

Identify value proposition (quantifiable) for order from box plant
VMI

Customer IT and Organizational Pain Points

In operation since Retrim
Reallocation
Detail Scheduling
Pulp

ABB 2004 in ABBs

Circuit Breaker
Transport.
Planning
Confirmation
Roll
Merger / Divestment
Confirmation
How to facilitate
Jumbo easy integration in merger/divestment cases: a new mill to Middleware
integrateMother
in anReel
existing corporate system; an existing mill to de-couple and join

Reel Registration

SAP
Registration
another company
plant in Dalmine,
ABB Oy / SAP AG 2004, SAP ABB Task Force / 39

Any RDBMS
Billing / Standardised ERP & MES products rolled out in parallel Database
Delivery WM Tracking QM
Invoicing Italy
ABB Group - 45 -

System architecture

Define possible integration scenarios Costing (FI, CO/PA)

If more and more tasks are moved into a central planning
Based on
- 95
system, it has to be assured by
the technical system architecture that the mills can be operated 24 x 365
If the central system requires mill information for decision making, it has to be assured
.NET technology
architecture provides a unbreakable data flow
that the technical system

Describe potential partnership scenarios Warehouse management:

Mill warehouses 24 x 365, often also integrated with the automation systems
ABB Oy / SAP AG 2004, SAP ABB Task Force / 48
23-Oct-17

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 -

inventory valuation?

ABB CPM
Devices ABB Historian ABB Controls 3rd party 3rd party
Historian controls
 Connecting to SAP View from 800xA

In 800xA, the structure required to

call the selected SAP function is
imported as a set of Aspect Objects.
ABB Group - 46 -
23-Oct-17
 Connecting to SAP View from 800xA

The complete SAP table is

now available in 800xA,
and we can subscribe to
SAP data in the same
manner as with process
Data.
ABB Group - 47 -
23-Oct-17
 ABB Group - 48 -
23-Oct-17

SQL / OLE DB / ODBC

 MES
ECS Enterprise Connection Solution
Point to Point Services Based
Integration ECS Benefits
Interfaces
Business Solution Open technology
ERP CRM SCM
Business Systems Reduced risk
SCM CRM ERP No need to rip and
Enterprise
xMII Interface replace
Integrated Lower TCO with
Composite
E Business Legacy Applications simpler systems
Integration
Plant
ECS Interface
ABB Group - 49 -

Plant Floor Systems

ABB and 3rd party control

23-Oct-17

systems, historians and CPM

 Industrial IT - Summary
800xA includes a very
comprehensive flexible batch
solution
Information Management as info
system with excellent reporting
and analyses tools
ECS incorporates MES
functionality and ERP connections
to e.g. SAP
800xA is flexible to delivery of
automation solutions that includes
the supply of or interface to
ABB Group - 50 -

third-party COTS software

23-Oct-17

products