isa s95-222
TRANSCRIPT
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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or itssusidiaries. All third party trademarks and service marks are the proprietary marks of their respective o!ners.
ISA S95
" #hat is it$ " #hy is it Important$ " #hy should Invensy %perations &anagement 'are$
(on 'lark, )ice *resident
+loal Industry olutions
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%-ectives
IA / %vervie!ighlights 3 A 4tutorial5
#hy it is important to the process industries
3 6nd user
3 )endor community
o! In7usion maps to /
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Topics
" The 8ig *icture
" #hy !as / 7ormed$
" )alue of / to the Industrial 'ommunity
" *rogress9to9(ate
" #hat the tandard is, #hat it 'overs, #hat it Isn:t
" #here !e are ;o!< 'urrent tatus, u9committee Activity, etc.
" Application to In7usion
" 7uture (irections
" / Impacts to %perating 'ompanies" 'all to Action=
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/< (efines (omain et!een (' and 6R*
/ > 4In7usion 'ore5 7unctionality
Traditional CIM gap based on time domain of interest Time domain of interest
?ears
&onths
#eeks
(ays
ours
&inutes
econds
&ilimicro seconds
'orporate6nterprise
*lant 'ontrolAutomation ystems
Gap of Unmet Needs
andled !ell y 6R* systemsandled !ell y 6R* systems
andled !ell yandled !ell y
('*@' systems('*@' systems
Result: Disconnect between that which is plannedand that which is, can, or ought to be done.
*urdue 'I&
Reference&odel
/ 4!eetspot5
4 4Invensys %perations &anagement5 In7usion 4'ore5 Invensys %perations &anagement5 In7usion 4'ore5
* r o d u c t i
on % p er a t i on s , or
6 n t er pr i s e ' on t r ol y s t e
m
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Reference &odel< #hy ave a tandard$
Integration of manufacturing control systems !ith the rest of the
usiness has een one of the more difficult prolems to solve;ot only technology issues, ut also people and organiational prolems
@ack of common terminology Bsame terms often used for different things ythe t!o groups, or different terms used for the same thingsC
@ack of consistent representation of data
)ie!points of !hat is important differ 'ritical success factors are different
At the very ottom, it casts !hat constitutes the information flo!set!een @evels D and @evel E in the *urdue 'I& Reference &odel in a!ay that is commonly availale to anyone, vendor and end user
It does not define !hat constitutes @evels D or E functionality, per se
%nly !hat constitutes activities between them
This means those functions that are involved in inter9@evel D and E messagingmust e like!ise defined
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)alue of /7or 6nd9Fsers<
*rovides reference to model their o!n usiness needs
Fse to define !hat components a pro-ect needs G incrementally
Fse to greatly reduce R7H pre9!ork G reduces to selection list
Re9use of I* across usinesses
Reduced learning curve for user and technical support< consistency
Reduces costs of inter9vendor interoperaility
Fsed in rational vendor selection evaluation< compare against a
4gold tandard5
7or olution *roviders<
*rovides consistent solutions across industry et!een customers
Allo!s for lo!er cost integration services
7aster deployments 7osters incremental solution deployments
(oes allo! room for innovationdifferentiation !ithin confines of tandard
@o!er pro-ect idding costs
%verall lo!er pro-ect costs and time
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2nd rev done!
Rev 2 update complete for review
2nd rev done=
Out for 1st vote!
Rev 2 update complete for review
The / tandard< The @ay of the @and 4Enterprise Control System Interation art 1" #odels and $erminoloy%
The scope of *art 1 is limited to<aC a definition of the scope of the manufacturing operations and control domain
C a definition of the organiation of physical assets of an enterprise involved in manufacturing
cC a definition of the functions associated !ith the interface et!een control functions and enterprise functions and
dC a definition of the information that is shared et!een control functions and enterprise functions.
&Enterprise Control System Interation art 2" O'(ect #odel Attri'utes%
The scope of *art 2 is limited to<3 the definition of attriutes for the *art 1 o-ect models.
3 the *art 2 standard does not define attriutes to represent the o-ect relationships defined in *art 1.
&Enterprise Control System Interation art )" Activity #odels of #anufacturin Operations%
The scope of *art D is limited to<3 A model of the activities associated !ith manufacturing operations and control, @evel D functions.
3 An identification of the data that flo!s among these activities.
&Enterprise Control System Interation art *" O'(ect #odels and Attri'utes of #anufacturinOperations #anaement%
;ote< This is a proposed *art E, defining detailed o-ect models of information that flo!s et!een the activities defined in*art D.
&Enterprise Control System Interation art 5" +usiness to #anufacturin $ransactions%
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*rogressive (etail J 6Kposure of / 'ommunication %-ects
" The / standard uses multiple models to eKplain the elements of 6nterprise'ontrol ystem Integration.
" The initial models in the standard are very astract, and the final models are very detailed and specific.
" 6ach model adds a level of detail and definition and uilds on the information in the previous model.
" The standard starts !ith a definition of the domain of manufacturing control and the general activitiesin the manufacturing domain.
" This is follo!ed y a model of the functions !ithin a manufacturing enterprise that relate, or interact,!ith the actual manufacturing control functions.
" The functions that are directly related to the scope of the standard are given additional definition and
descriptions, and then the information that flo!s et!een these functions is defined.
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/< ierarchy &odel B(omainsCA simplified version of the complete model defined in the *urdue Reference &odel for 'I&
B'omputer Integrated &anufacturingC, comined !ith the &6A B&anufacturing 6Kecution
ystems AssociationC model for activities in the manufacturing control domain.
ocus of !"# $art % & $art '
ocus of !"# $art ()#
*urdue
'I&
Reference
&odel
ocuses on *the process.+ The *ow+
ocuses on *the product.+ The *-hat+
* r o d u c t i on % p er a t i o
n s , or
6 n t e
r pr i s e ' on t r ol
y s t em
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/ eeks to 7ormalie and 4+enerisie5 for All *rocess&arkets these -orflow Activities and 7unctionsL
! lan,R epor t
rocess
#anufacturin Operations
*lanning9 year9Annual9&onthly9Ad hoc9'reates forecastsy product< 9 Fnit costs
9 )olumes 9 *lant loads 9 @aor needs 9 'apital assets
(etailed *roductioncheduling9(one y product9(one monthly98ased on volume plansand average rates96ach process unitline isscheduled9Real time scheduleoptimiation
*roduction Reporting9'ost9Huality9)olumes9Rates9#aste9y9cause
97orecasts
9Actuals
9)ariance
Ra! &aterials *urchasing9(one y product9According to schedule9Accommodates transport lags9%rderdeliver9Inventory levels9#I* storage9#arehouselocator system
9tage9hip
*roduction 6ngineering9(esign of 6Kperiments9Improve9*roduction Tech9support9*roduction Analysis
*roduction %perations9*roduction 6Kecution92EM support9(aily run time support9*rocess &onitoring 3 iK igma
*rocess 6ngineering9Automation9A*'9Rt%ps9*rocesseNuipment designs
Huality Assurance %perations98uilding Nuality in9(efining metrics9(efine standards and procedures9Incomingoutgoing inspections9&ake measurementsreport9*roduct Analysis
&aintenance %perations9*& schedules97iKrepaireKpensed9Improvecapitalied
hippingReceiving9@ogistics for shipping9Incomingoutgoing goods9&aterial dispatching
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*rocurementB.0C
*roductioncheduling
B2.0C
&aterial and6nergy 'ontrolBE.0C
*roductInventory 'ontrol
BM.0C
*roduct 'ostAccounting
BO.0C
HualityAssurance
BP.0C
Research(evelopment
and 6ngineering
*roducthipping Admin
B/.0C
%rder*rocessing
B1.0C
&arketingJ ales
*roduction'ontrolBD.0C
&aintenance&anagement
B10.0C
*ack %ut chedule
7inished +oods Inventory
7 i n i s h e d + o o d s #
a i v e r *rocess (ata
hort Term &aterial
and 6nergy ReNuirements
&aterial and 6nergyInventory
* r o d u c t i o n ' a p a i l i t y
* r o d u c t i o n 7 r o m * l a n
, c h e d u l e
I n c o m i n g m
a t e r i a l
a n d
e n e r g y r e
c e i p t
* r o d
u c t i o n
' o s t
% -
e c t i v e
s
* r o d u c t i o
n
* e r f
o r m
a n c e
a n d c o
s t
' o n f i r m t o s h i p
R e l e a s e t o s h i p
H A
R e s u l t
s
* r o d u c t
a n d
* r o c e s s
R e N u i r
e m e n t s
, t a n d a r d s a n d
' u s t o m e r
R e N u i r e m e n t s
, t a n d a r d s a n d ' u s t o m e r
R e N u i r e m e n t s
In *r ocess #aiver R e N u e s t
* r o c e s s ( a t a
H A R e s u l t s
* r o d u c t a n d * r o c e s s Q
n o ! 2 o !
* r o d u c t a n d * r o c e s s
I n f o r m a t i o n
R e N u e s t
& a i n t e n a n c e
R e N u
e s t s a n d , t a n d a r d s
& a
i n t e
n a
n c e
R e s p o n s e
a n d
7 e e d
a c k
&
a i n t e n a n c e
* u r c h a s e % r d e r
R e N u i r e m e n t s
& a t e r i a l a n d
6 n e r g y
R e N
u i r e m
e n t s
I n c o m i n g
% r d e r
' o n f i r m
a t i o
n
@ o n g
T e r m
& a t e
r i a l
a n d
6 n e r g y
R e N r : m
e n t s
This is #hat that @ooks @ike in /9speak<7unctional 6nterprise 'ontrol &odel< *art 1
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+usiness plannin- loistics information
*lant production scheduling,operational management, etc
#anufacturin operations- control information
*roduction operations, maintenanceoperations, Nuality operations, etc
*roduct
definitioninformation
B#hat must edefined to make
a productC
*roduction
capailityinformation
B#hat resourcesare availaleC
*roduction
scheduleinformationB#hat to
make and useC
*roduction
performanceinformationB#hat !as
made and usedC
*arts 1 and 2L
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I./OR#A$IO. /OR #A.0/AC$0RI. OERA$IO.S #A.AE#E.$
cheduleReNuest information *erformanceResponse information
*roductionschedule
&aintenancereNuest
Huality TestreNuest
*roductionperformance
&aintenanceresponse
Huality testresponse
*roductionoperations
management
&aintenanceoperations
management
Hualityoperations
management
'apaility information
Huality Testcapaility
&aintenancecapaility
*roductioncapaility
(efinition information
*roductdefinition
information
&aintenancedefinition
information
Huality testdefinition
information
Inventoryoperations
management
Inventorydefinition
information
InventoryreNuest
Inventoryresponse
Inventorycapaility
*arts 1, 2, and DL
#anufacturinoperations
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IA / &anufacturing Architecture
6nterprise application integration
*@& 6R* '& 'R&
A;IIA 3/ *art 1 and 2 %-ect model information
A;IIA 3/ *art D Activity models of &anufacturing %perations
$roduct definitionB!hat to makeC
$roduct capabilit/B!hat and ho! muchis availale to makeC
$roduct schedule B!hatto make and useC
$roduct response B!hat!as made and usedC
D e f i n i t i o n
! c h e d u l i n g
D i s p a t c h i n g
0 e s o u r c e M a n a g e
m e n t
1 2 e c u t i o n
D a t a c o l l e c t i o
n
$ e r f o r m a n c e 3 n a
l / s i s
T r a c . i n g
$roduction
4ualit/ Inventor/
Maintenance
$rocess Control 5ield instruments, DC!, $6C, sensors, etc.7
f
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&anufacturing %perationsInformation &odels B*art DC 6Kample
MAINTENANCE
OPERATIONS
MODEL
PRODUCTION
OPERATIONS MODEL
QUALITY
OPERATIONS
MODEL
Procurement(5.0)
Production
Scheduling
(2.0)
Material and
Energy Control(4.0)
Product
Inventory Control(7.0)
Product Cot
!ccounting
(".0)
#uality
!urance($.0)
%eearch
&evelo'ment
and Engineering
Product
Shi''ing !dmin
(.0)
rder Proceing
(*.0)
Mar+eting
, Sale
Production
Control(-.0)
MaintenanceManagement
(*0.0)
MAINTENANCE
OPERATIONS
MODEL
PRODUCTION
OPERATIONS MODEL
QUALITY
OPERATIONS
MODEL
Procurement(5.0)
Production
Scheduling
(2.0)
Material and
Energy Control(4.0)
Product
Inventory Control(7.0)
Product Cot
!ccounting
(".0)
#uality
!urance($.0)
%eearch
&evelo'ment
and Engineering
Product
Shi''ing !dmin
(.0)
rder Proceing
(*.0)
Mar+eting
, Sale
Production
Control(-.0)
MaintenanceManagement
(*0.0)
*rogressive (etail and 6Kposure
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Maintenance &odel from /, *art D
MaintenanceData
Collection
MaintenanceExecution
Maintenanceesource
Management
MaintenanceDispatching
Maintenance!racking
Maintenanceesponse
DetailedMaintenance"cheduling
Maintenancee#uest
MaintenanceDefnition
Management
MaintenanceCapability
Maintenance$nalysis
MaintenanceDefnitions
Level % and 2 E#uipment
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4ualit/ Test &odel from /, *art D
&ualitytest datacollection
&uality testexecution
&ualitytest resourcemanagement
&uality testdispatching
&uality testtracking
&uality testresponse
Detailed#uality testscheduling
&uality testre#uest
&ualitydenition
management
&uality testcapability
&ualityPerformanceanalysis
&uality testdenitions
Level % and 2 !est E#uipment
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Inventor/ &odel from /, *art D
!ransferdata
collection
!ransferexecution
!ransferresource
management
!ransferdispatching
!ransfertracking
'nventorytransferresponse
Detailedtransfer
scheduling
'nventorytransferre#uest
!ransferdenition
management
!ransferanalysis
'nventorytransfer
capability
'nventorytransfer
denitions
Level % and 2!ransfer e#uipment
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/< A #ork9in9*rogressL
" (ifficulties in applying the model in any literal: !ay<G ;o eKtensive real life industry eKamples are availale through !hite
papers, etc.
G Terminology mapping reNuired
" / descries generic structures Bnamevalue propertiesC for dataeKchange ut does not address ho! to enforce the meaning of thecontained dataG A / compliant: message generated y )endor A application may not e
meaningful to )endor 8:s application !hich supports / compliant:message interface
G ReNuire eKtra infrastructure to support eKchange of data, ut simplerthan none at all.
It is not a compliance9rich tandard.
It is a set of guidelines and a framewor <9 To align !ith, not comply to
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)endors and Technology Independence
$e pro'lem &anufacturing enterprises are typically dynamic entities. 'ontinual changes in
usiness processes are necessary to meet changing usiness and legal environments
3 The A;IIA / series of standards aids in separating usiness process fromproduction processes. It descries information in a !ay that is usiness 9 and production9 process independent
3 Another value of the standard to usiness is y separating the eKchanged informationfrom specific implementation of manufacturing systems and specific implementations of
the usiness systems.
$e solution 'onsidering the rate of change in usiness and manufacturing soft!are, a technology
independent !ay is needed to eKchange data. S&@ turns out the right solution at theright time. #hile multiples technologies can e used to eKchange S&@ documents, thedocuments themselves can e very stale across generations of technologies.
S&@ descried structured data in one document or application so that it can e usedy another application or document. 8y descriing the components and therelationships et!een them, S&@ can provide oth structure and meaning to any typeof data. S&@ is platform and vendor neutral.
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82&&@ 3 S&@ chemas for IA /
" An S&@ schema is an agreement et!een usinesses on ho! data
should e eKpressed in S&@
" In late 2001, a !orking group under the auspices of the #orld 8atch
7orum B#87C !as formed to produce a set of S&@ schemas for the data
models defined in IA9/.00.012
" 82&&@ provides a set of S&@ schemas ased on A;IIA9/
" 82&&@ may e used to integrate usiness !ith manufacturing systems
" #ill e revised per *art D once formally completed to include those S&@
schema as !ell 3 done
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#here #e Are TodayL
*arts 19E in final stages in re)do
ave rationalied *arts 1 3 *arts
ave formal interaction 'ommittees on inter9tandard Alliances<
&6A 3 possile marketing arm of / 'ommittee
OO#87 3 atch harmoniation 3 Tech paper completed &I&%A 3 &aintenance (ata access model
'%R 3 upply 'hain Reference &odel
// 3 'yersecurity
100 3 #ireless
10P 3 *rocedural Automation for 'ontinous *rocesses
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#hats FniNue aout the *rocess Industry$
1. &anufacturing is the location of a process companys Uvalue addU
2. &anufacturing has the greatest concentration of deployed capital in assets
D. &anufacturing employs the largest numer of people
&anufacturing is the est place to leverage laor productivity gains=
&anufacturing
'ommercial
RJ(
Administration
I
(istriutionof *ersonnel
upply 'hain
6ngineering
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6R* ystem
6nterprise %perations Integration
Asset &ap for *rocess Industries
*urchasingInound@ogistics
&anufacturing%utound@ogistics
%rder7ulfillment
Asset 8ase'apital (eployed
@aor&aterialinventory
6nergyIntellectual Qno!ledge
Information
V
%utside of RJ(, manufacturing is the only segment of a chemical companys supply chain !here value is added.
#anufacturin is te larest financial lever under a cemical company3s control4
&aterial)alue
)alue9Add
68IT
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The ;eKt %pportunity is 8et!een the
'ontrol Room and the 8oard Room
Enterprise
6nterprise 8usiness ystems
B6R*, 'ustomer Relationship &anagementC
Plant ProcessEquipment *rocess 'ontrol ystems
B'ontinuous, 8atch, (iscrete, 'A(ACensing and instrumentation
AutomateTransactions
Automate6vents
Automate6Nuipment
9/ &odel for &6
Manufacturing Networ
istorical(ata
&anagement
#ork6Kecution
*ersonnel, 6Nuipment, &aterials
Resource&anagement
#ork(ispatching
#orkTracking
#orkResponses
#orkcheduling
#orkReNuirements#ork
(efinition&anagement
*roductAnalysis BHAC
*rocess
Analysis
*roduction
Analysis
% p er a t i o
n al 6 K c el l en
c e
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%perational 6Kcellence< In7usionInvensys olution 7ootprint in the *rocess Industries
Enterprise
6nterprise 8usiness ystems
B6R*, 'ustomer Relationship &anagementC
Plant ProcessEquipment *rocess 'ontrol ystems
B'ontinuous, 8atch, (iscrete, 'A(ACensing and instrumentation
AutomateTransactions
Automate6vents
Automate6Nuipment
9/ &odel for &6
Manufacturing Networ
istorical(ata
&anagement
#ork6Kecution
*ersonnel, 6Nuipment, &aterials
Resource&anagement
#ork(ispatching
#orkTracking
#orkResponses
#orkcheduling
#orkReNuirements#ork
(efinition&anagement
*roductAnalysis BHAC
*rocess
Analysis
*roduction
Analysis
I n7 u s i on
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The In7usion )ision
In7usion ecomes the standard for6nterprise 'ontrol
(elivering integrated solutions that!ill unify the production and usinessenvironments
It !ill e as pervasive to theproduction environment as &icrosoft%ffice is for the desktop
Allo!ing our clients to<
Improve usiness J productivity 8/unif/ing disparate business s/stemsthat allow our clients a common viewfrom which the/ can drive their
operation %utperform the competition
8/ improving suppl/ chain efficienciesacross a multi site operation
'ontrol
8usiness Applications
Industrial (ata#arehouse
Intelligence6ngine
Real Time
Transactional
AdvancedApplications
7ield(evices
'ontrols
6nterprise 'ontrol ystem
'ore
&anufacturing%perations &anagement
8usiness%perations &anagement
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o! #e !ill (o It
'ontrol
8usiness Applications
Real Time
Transactional
6nterprise 'ontrol ystem
A p p l i c a t i o
n
6 n v i r o n m e
n t
6 n g i n e e r i n
g
6 n v i r o n m e
n t
I n 7 u s i o n
2 i s t o r i a n
A c t i v e 7 a c t o r y
I n f o r m a t i o
n
, e r v e r
A c c e s s
'ore
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6nterprise 'ontrol ystem Real9time %perations&anagement 4&arketecture5
oft!are ystem *latform
erticalIndustryApplications
@argeystem'ontrollers
BI*C
mallystem'ontrollers
B6FC
artners
.on,Invensys6evices Scala'le
CommonInfrastructure
Real,time
Operation#anaement
ApplicationSpace
7Cs
Ecosystem
4'ore5 technologies
afety'ontrollers
BI*C
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/:s Impact on %perating 'ompanies
" *rovides for rigorous documentation around common standards
" upports common !orkflo! processes
" 7aster scale upsshorter learning curves: due to standardiation
" Reduces documentation costs
" Allo!s for cross9industry migrations Nuickly
" *rovides eNual footing for end9user and regulatory agencies incommunications
" *romotes repetitive activities in support of standard
" Tighter linkage 3 repeatale, documented 3 et!eencontroleKecution and reportingplanning
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'all to Action
" ;eed for more end9user participation and involvement
" *articipation is free, and open to any interested party
" 6very company is entitled to one vote
" 'ontact either<
GQeith Fnger, 'hair< d-kungerWhotmail.com
G(on 'lark, 'o9'hair and F rep to I%I6' 'ommittees<
don.clarkWinvensys.com
G(ennis 8randl, 6ditor< dnrandlWrlconsulting.com
G'harley Roinson, IA tandards (irector< croinsonWIA.org
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]