manufacturing operations management l.
Download
Skip this Video
Loading SlideShow in 5 Seconds..
Manufacturing Operations Management PowerPoint Presentation
Download Presentation
Manufacturing Operations Management

Loading in 2 Seconds...

play fullscreen
1 / 35

Manufacturing Operations Management - PowerPoint PPT Presentation


  • 519 Views
  • Uploaded on

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

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'Manufacturing Operations Management' - Rita


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
manufacturing operations management

Manufacturing Operations Management

Dennis Brandl Peter Owen

BR&L Consulting Eli Lilly & Co

objectives
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
manufacturing in the supply chain
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
collaborative manufacturing help
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
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

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
philosophical orientation
Philosophical Orientation
  • Enterprise Management systems:
    • How much is my stuff worth?
  • Manufacturing Opearations Systems:
    • Where is my stuff?
isa 95 provides direction
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”
isa95 01 levels
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

isa95 01 levels9
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

isa 95 part 1 and part 2 exchanged information

ISA 95 Part 1 and Part 2 Exchanged Information

Information that crosses the boundary between business systems and manufacturing systems

exchanged information categories
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

4x4 object models
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
four resource object models

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

capability product schedule and performance information

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

production schedule

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
production performance

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, …

xml standard for b2m exchanges
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
an xml example material lot
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>

slide20

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

isa 95 03 manufacturing operations functions

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
other enterprise activities in manufacturing operations

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

implementations
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
building collaborative manufacturing systems
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
isa 95 control hierarchy levels
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

conceptual topology it view
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
conceptual topology it view27
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

functional areas
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
functional areas from isa 95 88
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

logical architecture
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
logical architecture it view

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

a physical architecture
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
physical architecture it view

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

conclusions
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
status
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