Industrial IT System 800xA ISA-95/S88 Standards Batch Information Management MES functionality
description
Transcript of Industrial IT System 800xA ISA-95/S88 Standards Batch Information Management MES functionality
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Industrial ITSystem 800xAISA-95/S88 StandardsBatchInformation Management MESfunctionality
Arto Lind
13 mars 2007
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ISA-95 Perspective on Manufacturing
Business Planning & Supply Chain
MgmtBusiness Process
transactions
Manufacturing Operations Management
ISA-95.01/02Definition
Production Definition
Production Capability
Production Plan
Production Information
Production Production Management Management TransactionsTransactions
Real-Time Control & Real-Time Control & EventsEvents
BatchBatchContinuous DiscreteDiscrete
ISA-95.03/04 Functionality
Level 0, 1, 2Level 0, 1, 2
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Sensors, Actuators and Logical Devices
ISA-95.05Functionality
Timeframe: Months, weeks, days, shifts
Timeframe: Day, Shift, Hour, Minutes, Seconds
Level 3
Level 4
ABB Coverage
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ISA S95 Standard Scope
SITE
AREA AREA AREA
CONTINUOUSPRODUCTION
UNIT
DISCRETEPRODUCTION
LINE
ISA95Standard
ENTERPRISE
95.0395.03
95.01 & .0295.01 & .02
BATCHPROCESS
CELL
ISA S88Standard
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Enterprise and Control Layers are Merging
Enterprise Layer
Control Layer
CPM Layer*
(if existing)
1995
Extended ERP
De
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Pro
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S
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Pro
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Re
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Ma
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Pro
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Da
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Ma
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Pro
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Da
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co
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Pro
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An
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Ma
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Pro
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Pro
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Extended Manufacturing
2005
Plant Instrumentation and Controls
Business Planning & Logistics Production Planning
ERP
DCS / PLC
SCADA
Manufacturing OperationsExecution and Control
MES
1985
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Platform for Control and CPM/MES One common platform for all manufacturing functions
Utilize modular 800xA software functions as required
Batch Management
Manufacturing Management
AssetOptimization
Common Operations, Engineering, & Data Management
Enterprise Connectivity Solutions (ECS)
Blending Granulation Tablet Coating Other OPC
Information Management
Real-Time Production Intelligence
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Enterprise Connectivity Solutions (ECS)
Web ServicesWeb Services
ISA-95
Specific AdaptorsSpecific Adaptors
ERP
Traditional InterfaceTraditional Interface
LIMS/DMS/etc
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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
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Production Operations
Productiondata
collection
Productionexecution
Productionresource
management
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Productdefinition
management
Production level 1-2 functions
ProductionPerformance
analysis
Productioncapability
Productdefinition
Equipment and processspecific production rules
Equipment and processspecific data
Operationalresponses
Operationalcommands
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ISA S95.03d Production Control Functions
ProductionCapability
ResourceManagement
HistoricalData
Management
ProductionExecution
ProductionDispatching
ProductionTracking
ProductionPerformance
DetailedProductionScheduling
ProductionSchedule
ProcessAnalysis
ProductionAnalysis
(QA) ProductAnalysis
ProductDefinition
Management
ProductDefinitions
AutomatedControl
ProcessMonitoring
ManualOperations
800xA Production Management
-Batch
800xA Information Management
800xA Operations
Supply ChainIntegration
ECS – EnterpriseConnectivity Solution
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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
What is 800xA Batch Management?System 800xA
Production Management
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ISA S88.01 Batch Standard
Procedure HierarchyProcedure HierarchyEquipment HierarchyEquipment Hierarchy
Area
Process Cell
Unit
Equipment Module
Procedure
Unit Procedure
Operation
PhaseWhatWhat
HowHow
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ISA S88 Procedure Hierarchy Production strategy organized by levels
Procedural elements can be used in multiple procedures
An element within a Procedure Function Chart (PFC) may represent another nested Procedure
InertInertUnit ready
Press > target
InitializeInitialize
Pressure
VentVent
ProcedureProcedure
Unit Unit ProcedureProcedure
PhasePhase
OperationOperation
An element within a PFC may launch and supervise sequential logic in process controller
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Product Definition Management
Procedure Function Chart (PFC) Editor provides a graphical workflow of operations and procedures
System 800xAProduction Management
Single master recipe for automated and manual production workflows
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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.
System 800xABatch Management
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Production Resource Management
View equipment status (Available, Busy, Reserved, etc.)
View Batch ID
View and change equipment attributes
View and manipulate reservation queue
System 800xAProduction Management
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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 batches
One-button duplicate feature
Simple utilities for Recipe, Resource, and Production Management
provide full functionality.
System 800xAProduction Management
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Production Schedule Interface
Enables interfaces from 800xA to external applications
Examples of actions supported Scheduling a batch
Retrieving status information
Changing batch state and parameters
Retrieving batch history variables
Provides complete access to information required for business system integration.
System 800xAProduction
Management
Batch Management
Manufacturing Management
Create Process
Order
Business System
Execute Process
Order
Upload Process
Order
System 800xABusiness System
ScheduleBatches
ProductionRecords
ProductionResponse(s)
ProductionRequest(s)
* ** Message broker / Transaction Mgr
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Functional Structure and Components
Engineering Production(68)
RCM(62)
DDRIVE(123)AO (29)
(68)
AO (29)
Control Recipes
Scheduler
Plant Explorer
Control & I/O
Operations
Batch Management
Server
InformationManagement
PDL
Production Orders
Production Orders Production
Reports
Production Reports
Control ProceduresBatch EventsOperator Comments
Numeric Trend DataControl & System EventsOperator Actions
ERP/MES Applications
Phases
Recipes
Operations
System 800xAProduction Management
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Common Equipment Model of System 800xA
Unit TypesInstances of
Physical Equipment
MasterRecipes
EquipmentGroups
ProcedureStructure
EquipmentStructure
FunctionalStructure
Object TypeStructure
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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.)
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Operator Workplace with Batch
Equipment Overview
Process Graphic
Procedure Function
Chart
Batch Overview
System 800xAProduction Management
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Flexible Recipe Management
Reusable recipe building blocks follow S88 batch 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
Improves production yields, minimizes scrap, and improves overall production profitability.
Procedure Function Chart Standard Operating
Procedure
System 800xAProduction Management
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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
Native language support
SOPs for Part 11 and cGMP
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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 providing useful information for making
intelligent business decisions.
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ISA S95.03d Production Control Functions
ProductionCapability
ResourceManagement
HistoricalData
Management
ProductionExecution
ProductionDispatching
ProductionTracking
ProductionPerformance
DetailedProductionScheduling
ProductionSchedule
ProcessAnalysis
ProductionAnalysis
(QA) ProductAnalysis
ProductDefinition
Management
ProductDefinitions
AutomatedControl
ProcessMonitoring
ManualOperations
800xA Production Management
-Batch
800xA Information Management
800xA Operations
Supply ChainIntegration
ECS – EnterpriseConnectivity Solution
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Desktop, Reporting & Analysis
Production Performance Analyses - Information Management
Process Data Alarm & Event Data Production Data
Control Room
Application Integration
ExternalProduction
Data(ERP, MES etc..)Archiving Engine
Data
Informationavailability
Information Management
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InformIT Information Manager Architecture
Information ManagerEnterprise Edition
Server
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Control Network
Seamless handling of historical data
Messages in the
800xA System
50k messages50k messages
1 sec /1 week1 sec /1 week
50k messages50k messages – – 12 million messages12 million messages
- 1sec / 10 years- 1sec / 10 years
1 sec /1 week1 sec /1 week
Trend logs in Connectivity
Server
Systemalarms/events
Audit Trail alarms/events
Process alarms/events
Real-time and History data
in History Server
Seamless view of all data
Archive
Operator Workplace/Desktop Display
Historical storage
OPC Data Access items: 40.000 itemsOPC update rate: > 0.1s (1s default)Primary logs/Con.Server: 5.000 logsPrimary logs/IM Hist.Server: 30.000 logs Updated min log values: 30.000/minReq. max buffer size: Con.Server: 3 months Max buffer size: IM Hist.Server: 10 years
Information Management
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Production Data Log
Robust data structures Correlation of batch history with continuous history (highly configurable -- doesn’t require custom code) Batch to Batch comparisons Pre-canned reports that can be used “right out of the box”
B
Batch 19/29/95 14:05:009/29/95 22:07:25
Job Name:Recipe Name:
Production Polystyrene grade 4Polystyrene_A4
Batch Name:Start T ime:End T ime:
Unit Procedure:Unitname:Start time:End time:
ReactionReactor R-1059/29/95 14:30:209/29/95 18:23:03
Phasename:start:initial temp:target temp:end:final temp:
Heat9/29/95 14:32:4023.5 Deg. C55.0 Deg. C9/29/95 16:35:1255.1 Deg. C
Batch 1
UnitProceedure 1
Operation
Batch 2
Campaign
Batch 1
UnitProceedure 1
B atch 2
Information Management
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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
Information Management
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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
Information Management
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Web ClientsInformation Management
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DeskTop Trend Trend Control
Tag Ticker
Presentation and NavigationInformation Management
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Softpoints & Calculation exempel
Softpoint object
Softpoint signals
Calculation aspect
Calculation script
User-defined data pointsTransform data into
actionable information
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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
Flexible Reports
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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
Security
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Campaign Name:Recipe Name:
Intermediate_S7_2004AXH Int_S7_Std
Unit Procedure:Unitname:Start time:End time:
ReactionRE1059/12/04 14:30:209/12/04 18:23:03
Operation name:Start time:
Heat9/12/04 14:32:10
Camp1
Batch 1
UP1
OPN 1
Batch 2
End time: 9/12/04 17:32:40
Batch_19/12/04 14:05:00
Batch Name:Start Time:End Time: 9/12/04 22:07:00
Production Data Collection / Tracking
Single common storage of batch record
Data stored according to batch recipe structure
All batch events, operator actions, system events, process alarms and events are stored
System 800xAInformation
Management
Complete electronic batch records
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ISA S95.03d Production Control Functions
ProductionCapability
ResourceManagement
HistoricalData
Management
ProductionExecution
ProductionDispatching
ProductionTracking
ProductionPerformance
DetailedProductionScheduling
ProductionSchedule
ProcessAnalysis
ProductionAnalysis
(QA) ProductAnalysis
ProductDefinition
Management
ProductDefinitions
AutomatedControl
ProcessMonitoring
ManualOperations
800xA Production Management
-Batch
800xA Information Management
800xA Operations
Supply ChainIntegration
ECS – EnterpriseConnectivity Solution
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Introduction
ECS
ECS Framework closes information gap between Business processes and the Manufacturing processes (machines, control systems).
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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 ISSUES IN CONTEXT
PRODUCTION REALITY – PLAN, RESPOND AND CHANGE ON DEMAND; NO MORE GUESSING
QUALITY DATA MANAGEMENT - RECOGNISE AND RESPOND TO QUALITY CHALLENGES
EVOLUTIONARY APPROACH - CONTINUOUS IMPROVEMENT
ECS =ECS =
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Levels
IT Framework
Manufacturing Framework
Applied Manufacturing Framework
Methodology and tools for modeling and implementation of solutions for different factories and manufacturing
Factory and domain specific deployments
800xA Core Platform
Reusable software components, fully integrated in 800xA Core Platform
domains.
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ECS Based Connectivity
ECS Makes Business Systems visible to the rest of the 800xA System as just another control equipment
800xACore
BusinessSystem
800M Controller
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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
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Manufacturing Process ExecutionManufacturing Process Modeling tool (S95)
ExecutableCode
BusinessSystem1Business
System1BusinessSystems
Devices
People(GUI)
Model-based Integration
Manufacturing ProcessDatabase
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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.)
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
Case: SAP PPPI – ABB 800xA Batch Management integration
SAPPP-PI
Control System
800xA Batch
ECS800xA IM
BAPIs, RFCs
SAP Control Recipe
Batch production data (consumption, confirmation, quantity produced)
MES
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Task forceresults withrecommendations
2004-04-12
Development of the ABB-SAP Joint Solution
2004-04
ABB-SAPCo-operationinitiated
20062004-12
Sapphire Paris
Joint solutionready to deploy
2005
Joint solutiondevelopment
ABB-SAPTask forcePulp & Paper
Initial industry: Pulp & PaperTaskforce Charter:
Define appropriate customer segmentation (products, regions,…)
Identify pain points of the different customer groups
Determine where there are pain points which are significant and where we can find/have a combined solution
Identify value proposition (quantifiable) for Customer ABB SAP
Define possible integration scenarios
Describe potential partnership scenarios
Detailed analysis of production and business processes of various P&P industry segments17 workshop sessions, 8 months
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PaperMachine Simplex
Sheeter
SimplexSheeter
Winder
Rewinder
Folio (Customer sizes)/ CutSize (Standard sizes)Sheets
Rolls
PalletWrap
RollWrap
Warehouse
Custom
ers
CoaterRe-
reelerSC
Winder
Not all machines are displayed on this slide
Material Flow Example – Fine Paper
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Linerboard Example
CustomerOrder Entry
ATPCheck
Prod. Plan.Winder
Prod. PlanPaper Mach.
PlanningPulp
ConfirmationRoll
ConfirmationJumbo
RetrimReallocation
Tracking QMDeliveryBilling /
Invoicing
Transport.Planning
WM
Costing (FI, CO/PA)
• Evt. stock transferorder from box plant
• VMI
„Reel Registration“ „Mother Reel Registration“
Detail SchedulingPulp
Forecast orReplenishment
CTPCheck
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IT and Organizational Pain Points
Merger / Divestment
How to facilitate easy integration in merger/divestment cases: a new mill to integrate in an existing corporate system; an existing mill to de-couple and join another company
Standardised ERP & MES products rolled out in parallel
System architecture
If more and more tasks are moved into a central planning 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 that the technical system architecture provides a unbreakable data flow
Warehouse management:
Mill warehouses 24 x 365, often also integrated with the automation systems (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 inventory valuation?
Taskforce results and recommendations presented to management
Agreed to continue to concrete actions:
Pilot customers
Integrated scenarios refined
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Dynamic CTP + order profitability
ABB ProductionExecution
WraplineWarehousing
Shipping
Sheeting
ReelProcessing
Paper MachineDry End
WIPStorage
Rolls
APO
ATP/CTP Block planning Demand Forecasting
ATP/CTP Check 80%
Pallets
DeliveriesWarehouse Status
ConfirmedOrders
Rolls
ProductionStatus
ProductionStatus
Patterns Patterns
Patterns
RewinderRunSchedule
RunSchedule
Rolls
SAP ERP
Reels
Industrial IT Production Planning
Trim & Finishing operationsOptimization
RollsReelsWinder
PTPCheck20%
Run Scheduling1-2 weeks, dynamic
Schedule OptimizationPTP
ABB ProductionScheduling
SAP SalesDistributionPlanning
ConfirmedOrdersOptimized Run Schedule
OptimizedBlock ScheduleAllocations/Replenishment
Forecasts
ABB-SAP Joint Solution
Concrete developmentABB CPM Connector for Pulp & PaperABB ECS frameworkSAP Connectivity and Netweaver certification
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ECS – Overview
In operation since 2004 in ABB’s Circuit Breaker plant in Dalmine, Italy
Based on
.NET technology
- 95
Any RDBMSDatabase
ABB ControlsDevices 3rd party controls
ABB Historian 3rd party Historian
ABB CPM
Database
Middleware
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ECS is ABB’s standard for integration to SAP
Chemicals,
Pharma, F&B
Metals Pulp &
Paper Oil & Gas
Offshore
800xA BatchCPM@Metals CPM for Paper PIMS apps.for O&G
Cement &
Minerals
KnowledgeManager
CPM
DCS
Oil & Gas
Onshore
SCADA Vision
Enterprise Connectivity Solutions (ECS)
800xA
ABB and 3rd party control systems and historians
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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.
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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 processData.
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SQL / OLE DB / ODBC
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ECS – Enterprise Connection Solution
Open technology
Reduced risk
No need to rip and replace
Lower TCO with simpler systems Integration
Point to Point Interfaces ECS Benefits
ERPCRM
E Business
Plant Floor Systems
Business Systems
SCM
Legacy
EnterpriseInterface
Business Solution
ECSPlant
Interface
ERP CRM SCM
xMII
ABB and 3rd party control systems, historians and CPM
Integrated Composite
Applications
Services Based Integration
MES
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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” third-party COTS software products