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Transforming Manufacturing Operations
A Discussion with Charlie Gifford
Chairman of ISA-95 Best Practices Working Group
21st Century Manufacturing Solutions LLC
ISA-95 Best Practices Working Group
ISA-95 implementation and technical best practices
• “As-Is” manufacturing operations as a defined reference
model for MOM Requirements
• Establish a common terminology and data models
• Characterize the “To-Be” manufacturing operations
• Describe transformation migration path
• 24 White Papers in True Peer Review Process
• Over 48 Authors and 76 Reviewers from 18 countries
• The Hitchhiker’s Guide to Manufacturing Operations
Management: ISA-95 Best Practices Book 1.0 (2007)
• When Worlds Collide in Manufacturing Operations:
ISA-95 Best Practices Book 2.0 (2011)
• The MOM Chronicles: ISA-95 Best Practices Book 3.0 (2013)
ISA-95 Best Practices Working Group
Book 3.0 Dedicated
to Ray Bradbury
The Manufacturing Operations Paradox
Column1
Cultural
Technical
“The first rule of any technology used in a business is that automation applied to an efficient operation will magnify the efficiency. The second is that automation applied to an inefficient operation will magnify the inefficiency.” Bill Gates, Founder of Microsoft
The Manufacturing Operations Paradox
Book 3.0 White Papers / Chapters
1. Applying Global MOM Systems in a Manufacturing 2.0 Approach
2. The Role of Semantic Models in Smarter Industrial Operations
3. Applying Manufacturing Operations Models in a Discrete Hybrid Manufacturing Environment
4. Defining an Operations Systems Architecture
5. A Workflow-driven Approach to MOM
6. Scheduling Integration Using an ISA-95 Application in a Steel Plant
7. Intelligent Integration Interface: A Real-world Application of ISA-95
Book 3.0 Focus
• Current manufacturing leaders have a limited vision how their
plants must competitively operate in global markets in 2025
• Manufacturers do not have a concept of high engineering cost
required to transform their paper-based operations into real-time
artificial intelligence for their work processes
• The proven reality of manufacturing operations is that
manufacturing innovation requires an iterative continuous
improvement process using MOM systems engineering
• By 2025, those manufacturers without paperless work processes
for intelligent operations simply will not compete
• Book 3.0 lays out the foundation
Book 3.0 Focus • Explains MOM system engineering methods for organizing the
complexities of a 21st century manufacturing plant to optimize its
role in a global supply chain
• Stresses to not trivialize operations as simply a problem of an
equipment optimization or material quality or consumption
• Explains the operations process definition as the MOM Master
User Requirement Specification to map out the As-Is inefficient
and To-Be reengineered efficient operations supported by the
Operations System Architecture (OSA)
• To-Be operations process definition determines operations
dependencies of each plant in its global supply network
• Mfg Master Data Management through Semantic Computing
Development Steps of an OSA
Aligned with Business Drivers
Crude
Feedstock
Operations
Customer
Order
Feedstock
Management
Billing
User Level
Tasks
Group Level
Tasks
Operations
Level
Workflows
Enterprise
Level
Business
Process
Horizontal
Integration
Vertical
Integration
Manufacturing Intelligence through
Orchestrated Workflows
Execute Path
Selection
Lineup
Execute Tank
Swing
Calibrate
Analyzer
Check Crude
Feedstock
Prop
Feedstock
Sampling
Feedstock
Tank Swing
Operations Systems Integration Evolution
Monolithic
Architectures
Pre 1950’s
to 1960’s
1970’s to
Mid-1980’s
Mid-1990’s to
Early 2000’s
Late 1990’s
Centralized
Applications
& Database
Objects- Owning Data (Remote Invocation)
Message Oriented
Information Exchange
EAI (Brokered Data Exchange)
1980’s to
Mid-1990’s
Early 2000’s
SOA
Mid-2000’s to
Present
Emerging Today
Semantic Computing
IOA
(Information
Oriented
Architecture)
Manufacturing Master Data Management
through Semantic Computing
Questions?
A Conversation with
Charlie Gifford 21 Century Manufacturing Solutions LLC
Link to Recorded Webinar
Charlie Gifford Chair, ISA-95 Best Practices Working Group
President & Chief Manufacturing Consultant
21st Century Manufacturing Solutions LLC
O: 208-788-5434
M: 208-309-0990
F: 208-788-5690