Road to integration - inkijkexemplaar

THE ROAD TO INTEGRATION

A GUIDE TO APPLYING THE ISA-95 STANDARD I N M A N U FA C T U R I N G

BIANCA SCHOLTEN

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The Road to Integration A Guide to Applying the ISA-95 Standard in Manufacturing

By Bianca Scholten

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Author Images Layout & cover design Translation

Bianca Scholten Bettina Logge-Mensing APR Groep bv Grayson Morris

Photo and Artwork Credits

• Cover and Figure 53 M.C. Escher’s Relativity, © 2006 The M.C. Escher Company B.V. - Baarn - the Netherlands. All rights reserved.

• Photo Figure 1 Pieter Brueghel the Elder, The Tower of Babel, Courtesy of the Boymans-Van Beuningen Museum, Rotterdam, the Netherlands.

• Figure 16 © René Magritte, The Treachery of Images, 1929 c/o Beeldrecht Amsterdam 2006.

Photo Figure 16 La Trahision des images (Ceci n’est pas une pipe), 1929, René Magritte, museum number 78.7, Courtesy of the Los Angeles County Museum of Art, purchased with funds provided by the Mr. and Mrs. William Preston Harrison Collection, Los Angeles, CA, USA, Photograph © 2006 Museum Associates / LACMA • Figure 23 © Jackson Pollock, Reflection of Big Dipper, c/o Beeldrecht Amsterdam 2007 Photo Figure 23 Courtesy of the Stedelijk Museum Amsterdam.

• Author portray Courtesy of Frank van Driel Fotografie, Vught, the Netherlands, www.frankvandriel.com.

Copyrights

Copyright © 2007 by

All rights reserved

ISA- Instrumentation, Systems, and Automation Society 67 Alexander Drive P.O. Box 12277 Research Triangle Park, NC 27709

Printed in the United States of America.

ISBN-13: 978-0-9792343-8-5 ISBN-10: 0-9792343-8-7 No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.

Notice

The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use.

The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application. Additionally, neither the author nor the publisher have investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented.

Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author nor the publisher make any representation regarding the availability of any referenced commercial product at any time. The manufacturer’s instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication. iii

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Library of Congress Cataloging-in-Publication Data Scholten, Bianca.

The road to integration: a guide to applying the ISA-95 standard in manufacturing /

by Bianca Scholten. p. cm.

Includes bibliographical references and index.

ISBN 978-0-9792343-8-5 (alk. paper) 1. Production control--United States--Standards. I. Title.

T56.8.S53 2007 658.5’1--dc22 2007004422

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Foreword

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The Road to Integration: A Guide to Applying the ISA-95 Standard in Manufacturing

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Foreword

Foreword What would you call IT integration projects that had under a 50% success rate, took more than two years on average, and rarely ever meet the original requirements? The term “failure” would be my top choice, yet this was the state of the art in ERP-to-shop-floor integration projects prior to the use of the ISA-95 Enterprise/Control System Integration standard and B2MML, the WBF Business To Manufacturing Markup Language. These two standards have changed the landscape of ERP-to-shop-floor integration, transforming risky and expensive integration projects into low risk and affordable integration projects. The payoff for these projects can be very large, as manual and error prone processes are replaced with near real-time automated data transfers. Several companies have reduced their final inventory by over 60%, freeing up hundreds in millions of dollars for other investments. ERP systems need massive amounts of data, and much of that data comes from the shop floor. When manual data entry and reconciliation processes with long delays in data entry are replaced with near real-time information, then ERP reports and predictions can be based on actual values instead of estimates.

Yet, despite the advantages obtained by using the ISA-95 and B2MML standards, they are not well known outside of manufacturing automation departments. This book by Bianca Scholten provides an excellent explanation of the standards and a tutorial that intertwines definitions, end user quotes, and real integration project stories. This book will allow you to understand many of the complex concepts in the ISA-95 standard using simple examples and stepby-step plans for integration projects. This will provide invaluable help to any ERP-to-shop-floor integration project.

When the ISA SP95 committee started work on the ISA-95 standard, there was a lot of confusion in the marketplace. Sales personnel for ERP systems rarely understood any of the complexity of the shop floor systems and sometimes made extravagant claims of the ERP applicability to shop floor and real-time processes. Likewise sales personnel for shop floor systems, such as DCS, PLC, and SCADA systems, rarely understood the complexity of their customer’s business processes and minimized the issues of integration. I, like many members of the SP95 committee, had been involved in multiple integration projects and had seen good, bad, and ugly integration projects and MES projects.

We also knew that if we could capture the best processes and best practices then we could help any manufacturing company.

Even though many of the original committee members came from the process industries (chemical, food and beverage, pharmaceutical, consumer products) the goal was always to address the full range of manufacturing types, from airplanes to zippers. This was an ambitious goal, and it took a lot of hard work by the volunteer members of the committee. It also took the commitment of control system vendors and ERP vendors, to support their employees during the six year development. There were personal commitments by members to finish the standards, with several individuals working on the standards despite job changes, company changes, a recession, and even layoffs. The result was a set of standards that have been widely useful, in industries as diverse as

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The Road to Integration: A Guide to Applying the ISA-95 Standard in Manufacturing

food production, oil pipelines, automotive manufacturing, and biotechnology.

The standards have allowed IT professionals, manufacturing professions, and business professionals to share a common language and a common model for integration. The ISA-95 standard also provides the first formal model for the functions normally identified as MES (Manufacturing Execution Systems), allowing companies to compare different vendor solutions, and even more importantly, compare operations in their own manufacturing sites.

Like any standard, the ISA-95 standard and IEC 62264, the international version, was a consensus document. It reflects the experience of hundreds of experts from dozens of companies and countries. Because of this diversity of backgrounds and depth of experience, we were not able to capture in the standard all of the knowledge shared in the meetings. We knew that the best methods to apply the standards also needed to be refined and documented. Bianca’s book is an important supplement to the standards, capturing in tutorial format what we were unable to put into the standards. I hope that you learn as much from reading this book as I did, the comments and quotes from the early adopters of the standards provide valuable lessons for anyone starting an ERP-to-shop floor integration or MES project.

Dennis Brandl Editor of the ISA-95 standard

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About the Author

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The Road to Integration: A Guide to Applying the ISA-95 Standard in Manufacturing

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About the Author

Bianca Scholten is a partner at Ordina, one of the largest publicly traded consultancy service providers in the Netherlands and Belgium in the areas of information and communication technology and management. She was the driving force behind the inception of the Ordina ISA-95 & MES Competence Center. Ms. Scholten advises national and international industrial companies on how to determine their manufacturing automation strategies. She has trained hundreds of professionals in applying ISA-95, mostly in Europe. Ms. Scholten is an active member of the SP95 committee. She publishes regularly in trade journals and frequently speaks at conferences on subjects related to vertical integration and technical automation. In addition to these areas of expertise, Ms. Scholten is also an art historian. She received her Masters degree from the University of Utrecht, the Netherlands, in 1993.

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The Road to Integration: A Guide to Applying the ISA-95 Standard in Manufacturing

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Table of Contents

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Table of Contents

Introduction

....................................................................................................... 21

Chapter 1: Getting Acquainted with ISA-95 ........................................................ 25 1.1 Introduction ................................................................................... 26 1.2 History of the Development of ISA-95 ........................................... 26 1.3 Objective and Content of ISA-95 ................................................... 27 1.3.1 Part 1 ..............................................................................................28 1.3.2 Part 2 .............................................................................................. 37 1.3.3 Part 3 .............................................................................................. 39 1.3.4 Part 4 .............................................................................................. 45 1.3.5 Part 5 .............................................................................................. 46 1.4 Opportunities for Applying ISA-95 ................................................ 47 1.4.1 ISA-95 as an Analysis Tool ............................................................ 48 1.4.2 ISA-95 Applied to the Development of MES Applications ............ 50 1.4.3 ISA-95 Applied for Vertical Integration.......................................... 52 1.5 Advantages of Applying ISA-95 ..................................................... 54 1.6 The SP95 Committee...................................................................... 55 1.7 The ISA-95 Hype ........................................................................... 58 1.8 The Future of (and with) ISA-95 .................................................... 60 1.9 Summary ........................................................................................ 61 Notes .............................................................................................. 63 Chapter 2: Applying ISA-95 as an Analysis Tool ..................................................67 2.1 Introduction .................................................................................... 68 2.2 Why Perform an ISA-95 Analysis? ................................................. 68 2.3 The Steps in an ISA-95 Analysis .................................................... 69 2.4 Preparation and Methodology......................................................... 70 2.4.1 Written Input or Interviews ............................................................ 70 2.4.2 Determine the Scope ...................................................................... 71 2.4.3 Select Employees for Interviews ....................................................71 2.4.4 Schedule the Steps of the ISA-95 Analysis ..................................... 71 2.4.5 Prepare to Conduct the Interview Sessions ..................................... 75 2.4.6 Process the Information .................................................................. 77 2.4.7 The Analysis Deliverables .............................................................. 77 2.5 Getting Down to Work ................................................................... 82 2.5.1 Step 1: A Tour of the Company ..................................................... 82 2.5.2 Step 2: Determine the Scope and the Business Drivers ................... 82 2.5.3 Step 3: The Functional Hierarchy Model ........................................ 83 2.5.4 Step 4: The Equipment Hierarchy Model and Process Segments .... 86 2.5.5 Step 5: The Functional Enterprise-Control Model .......................... 91 2.5.6 Step 6: The Production Operations Management Activity Model ... 93 2.5.7 Step 7: The Maintenance Operations Management Activity Model 96 2.5.8 Step 8: The Quality Test Operations Management Activity Model . 98 2.5.9 Step 9: The Inventory Operations Management Activity Model ... 100 2.5.10 Step 10: Other Activities Important on Level 3 ............................ 102 2.6 Writing the Conclusion and Recommendations ............................ 103 xv

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2.6.1 2.6.2 2.6.3 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 2.7.6 2.8 2.8.1 2.8.2 2.9

Summary of the Most Important Findings and Points of Concern . 103 A Proposal for the Follow-up Trajectory ...................................... 104 Points of Concern for the Follow-Up Trajectory ........................... 105 Points of Concern in an ISA-95 Analysis ..................................... 105 Pitfalls during the Preparatory Phase ............................................ 106 Pitfalls during the Interview Sessions ........................................... 107 Pitfalls during the Processing Phase ............................................. 110 Pitfalls during the Conclusion ...................................................... 112 General Pitfalls ............................................................................ 112 Summary ...................................................................................... 113 End Users’ Experiences with ISA-95 Analyses ............................. 114 Aviko’s Investigation into SAP and MES ..................................... 114 Abbotts Investigation into Electronic Batch Records.................... 115 Summary ...................................................................................... 117 Notes ............................................................................................ 119

Chapter 3: Understanding and Applying the ISA-95 Object Models ................ 123 3.1 Introduction .................................................................................. 124 3.2 Object Models The How and Why ................................................ 124 3.3 General Description of the Object Models .................................... 125 3.3.1 From Thirty-one Information Flows to Nine Object Models ......... 125 3.3.2 UML Models ................................................................................ 125 3.3.3 Tabels, Attributes and Properties .................................................. 126 3.3.4 IDs ............................................................................................... 127 3.4 Example: That’s Y Furniture ........................................................ 128 3.5 The Resource Models ................................................................... 129 3.5.1 Personnel ..................................................................................... 130 3.5.2 Equipment .................................................................................... 132 3.5.3 Material ........................................................................................ 134 3.5.4 Process Segment .......................................................................... 136 3.6 The Remaining Models ................................................................ 138 3.6.1 Production Capability ................................................................... 138 3.6.2 Product Defintion Information ...................................................... 142 3.6.3 Production Schedule ..................................................................... 148 3.6.4 Production Performance .............................................................. 152 3.7 Other Points of Concern ............................................................... 155 3.7.1 UML Classes and ISA-95 Objects ................................................ 155 3.7.2 ISA-88 or ISA-95 ......................................................................... 156 3.8 Case Study ................................................................................... 156 3.8.1 Logistics or Production? ............................................................... 157 3.8.2 The ISA-95 Configuration ............................................................ 157 3.8.3 Specific Scheduling Problems and Their Solutions ....................... 159 3.8.4 Using the Application in Other Enterprises .................................. 160 3.9 Summary ...................................................................................... 161 Notes ............................................................................................ 163

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Table of Contents

Chapter 4: Applying ISA-95 to Vertical Integration .......................................... 167 4.1.

Introduction .................................................................................. 168 4.2 Integration Theories ..................................................................... 168 4.2.1 What is Vertical Integration? ........................................................ 168 4.2.2 Why Integrate Vertically? Why Standardize? ............................... 170 4.3 The ISA-95 Integration Architecture ............................................ 173 4.3.1 Introduction .................................................................................. 173 4.3.2 XML and B2MML ....................................................................... 173 4.3.3 Middleware .................................................................................. 176 4.3.4 Adapters ....................................................................................... 178 4.3.5 The Role of ISA-95 Part 5 in the Integration Architecture ............ 179 4.4 Integration of Enterprise and Control Systems Using ISA-95 ....... 180 4.4.1 Step-by-Step Plan ......................................................................... 180 4.4.2 Subsequent Phases in the Integration Project ............................... 185 4.5 Points of Concern ......................................................................... 186 4.5.1 Master Data Management ............................................................. 186 4.5.2 Who’s the Owner? ....................................................................... 188 4.5.3 Status of B2MML Support among ERP and MES Vendors ........... 190 4.5.4 The Status of B2MML.................................................................. 190 4.6 Summary ...................................................................................... 190 Notes ............................................................................................ 193 Glossary

..................................................................................................... 197

Appendix

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Bibliography

..................................................................................................... 207

Index

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Figure index

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Introduction

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