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Industrial IT System 800xA ISA-95/S88 Standards Batch Information Management MES functionality

Industrial IT System 800xA ISA-95/S88 Standards Batch Information Management MES functionality. Arto Lind. 13 mars 2007. Business Planning & Supply Chain Mgmt. Business Process transactions. Production Definition. Production Capability. Production Plan. Production Information.

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Industrial IT System 800xA ISA-95/S88 Standards Batch Information Management MES functionality

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  1. Industrial ITSystem 800xAISA-95/S88 StandardsBatchInformation Management MESfunctionality Arto Lind 13 mars 2007

  2. Business Planning & Supply Chain Mgmt Business Process transactions Production Definition Production Capability Production Plan Production Information ISA-95.01/02 Definition ISA-95.05 Functionality Manufacturing Operations Management Production Management Transactions ISA-95.03/04 Functionality Batch Discrete Real-Time Control & Events Continuous Manufacturing Facility Sensors, Actuators and Logical Devices Level 0, 1, 2 ABB Coverage ISA-95 Perspective on Manufacturing Level 4 Timeframe: Months, weeks, days, shifts Level 3 Timeframe: Day, Shift, Hour, Minutes, Seconds

  3. ENTERPRISE AREA AREA AREA 95.01 & .02 95.03 ISA S88 Standard SITE ISA95 Standard DISCRETE PRODUCTION LINE CONTINUOUS PRODUCTION UNIT BATCH PROCESS CELL ISA S95 Standard Scope

  4. 1995 2005 Business Planning & Logistics Production Planning ERP Extended ERP Enterprise Layer Manufacturing Operations Execution and Control MES SCADA Detailed Production Scheduling Product tracking CPM Layer* (if existing) Production Resource Management Production analysis Product Analysis Production Data collection Maintenance management Product Data Management DCS / PLC Plant Instrumentation and Controls Extended Manufacturing Control Layer Enterprise and Control Layers are Merging 1985

  5. Information Management LIMS/DMS/etc ERP ISA-95 Specific Adaptors Traditional Interface Web Services Enterprise Connectivity Solutions (ECS) Real-Time Production Intelligence Enterprise Connectivity Solutions (ECS) Batch Management Manufacturing Management Asset Optimization Blending Other OPC Granulation Coating Tablet Platform for Control and CPM/MES • One common platform for all manufacturing functions • Utilize modular 800xA software functions as required Common Operations, Engineering, & Data Management - - - - - - - - - - - - - - - - Real-time Data Sources- - - - - - - - - - - - -

  6. 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

  7. Product definition Production capability Production schedule Production performance Detailed production scheduling Production tracking Production resource management Production Performance 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 Production level 1-2 functions Production Operations

  8. Product Definitions Production Capability Production Schedule Production Performance Detailed Production Scheduling Production Tracking Resource Management (QA) Product Analysis Production Dispatching Historical Data Management Process Analysis Product Definition Management Production Execution Production Analysis 800xA Operations Process Monitoring Automated Control Manual Operations ISA S95.03d Production Control Functions Supply Chain Integration ECS – Enterprise Connectivity Solution 800xA Information Management 800xA Production Management -Batch

  9. System 800xA Production Management What is 800xA Batch Management? 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

  10. ISA S88.01 Batch Standard Equipment Hierarchy Procedure Hierarchy Area Procedure How Unit Procedure Process Cell What Unit Operation Equipment Module Phase

  11. Procedure Initialize Unit ready Unit Procedure Inert Pressure Press > target Operation Vent Phase 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 • An element within a PFC may launch and supervise sequential logic in process controller

  12. System 800xA Production Management Product Definition Management • Procedure Function Chart (PFC) Editor provides a graphical workflow of operations and procedures Single master recipe for automated and manual production workflows

  13. System 800xA Batch Management 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.

  14. System 800xA Production Management Production Resource Management • View equipment status (Available, Busy, Reserved, etc.) • View Batch ID • View and change equipment attributes • View and manipulate reservation queue

  15. System 800xA Production Management 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.

  16. System 800xA Production Management Execute Process Order Upload Process Order Create Process Order Business System Business System System 800xA Batch Management Production Request(s) Production Response(s) Schedule Batches Production Records * * * Message broker / Transaction Mgr Manufacturing Management 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.

  17. System 800xA Production Management Recipes Operations Control Recipes Phases (123) DDRIVE (29) AO (68) (62) RCM (29) AO (68) Functional Structure and Components ERP/MES Applications Scheduler Production Orders Production Reports Information Management PDL Batch Management Server • Control Procedures • Batch Events • Operator Comments Plant Explorer Operations • Numeric Trend Data • Control & System Events • Operator Actions Control & I/O Engineering Production

  18. Common Equipment Model of System 800xA Procedure Structure Object TypeStructure FunctionalStructure EquipmentStructure Master Recipes EquipmentGroups Instances ofPhysical Equipment Unit Types

  19. 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.)

  20. System 800xA Production Management Operator Workplace with Batch Equipment Overview Batch Overview Procedure Function Chart Process Graphic

  21. System 800xA Production Management Flexible Recipe Management Improves production yields, minimizes scrap, and improves overall production profitability. • 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 Standard Operating Procedure Procedure Function Chart

  22. 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

  23. 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 Batch Production Data Management The hierarchical data storage greatly facilitates batch to batch analysis quickly providing useful information for making intelligent business decisions.

  24. Product Definitions Production Capability Production Schedule Production Performance Detailed Production Scheduling Production Tracking Resource Management (QA) Product Analysis Production Dispatching Historical Data Management Process Analysis Product Definition Management Production Execution Production Analysis 800xA Operations Process Monitoring Automated Control Manual Operations ISA S95.03d Production Control Functions Supply Chain Integration ECS – Enterprise Connectivity Solution 800xA Information Management 800xA Production Management -Batch

  25. Information Management Desktop, Reporting & Analysis External Production Data (ERP, MES etc..) Application Integration Control Room Production Data Process Data Alarm & Event Data Production Performance Analyses - Information Management Information availability Archiving Engine Data

  26. InformIT Information Manager Architecture Information ManagerEnterprise EditionServer

  27. Information Management Seamless handling of historical data Operator Workplace/Desktop Display Messages in the 800xA System Real-time and History datain History Server Seamless view of all data Systemalarms/events – 12 million messages 50k messages 50k messages Audit Trail alarms/events - 1sec / 10 years 1 sec /1 week Process alarms/events Archive Historical storage Trend logs in Connectivity Server 1 sec /1 week OPC Data Access items: 40.000 items OPC update rate: > 0.1s (1s default) Primary logs/Con.Server: 5.000 logs Primary logs/IM Hist.Server: 30.000 logs Updated min log values: 30.000/min Req. max buffer size: Con.Server: 3 months Max buffer size: IM Hist.Server: 10 years Control Network

  28. Information Management Job Name: Production Polystyrene grade 4 Campaign Recipe Name: Polystyrene_A4 Batch Name: Batch 1 B a t c h 1 B a t c h 1 Start T ime: 9/29/95 14:05:00 End T ime: 9/29/95 22:07:25 Unit Procedure: Reaction Unit Unit Unitname: Reactor R-105 Proceedure 1 Proceedure 1 Start time: 9/29/95 14:30:20 End time: 9/29/95 18:23:03 Phasename: Heat Operation start: 9/29/95 14:32:40 initial temp: 23.5 Deg. C target temp: 55.0 Deg. C end: 9/29/95 16:35:12 B a t c h 2 B a t c h 2 final temp: 55.1 Deg. C 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

  29. Information Management 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

  30. Information Management 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

  31. Information Management Web Clients

  32. Information Management Presentation and Navigation • DeskTop Trend • Trend Control • Tag Ticker

  33. Softpoints & Calculation exempel Transform data into actionable information User-defined data points Calculation aspect Softpoint object Calculation script Softpoint signals

  34. Flexible Reports Flexible Report generation & distribution • Microsoft Excel, Crystal Report • Real time data, historical, lab data, batch- and event-information • Reportgeneration • Printer • Email • Historical archiving • Lolal- or network-disc

  35. Security 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

  36. System 800xA Information Management Campaign Name: Intermediate_S7_2004AXH Recipe Name: Int_S7_Std Camp1 Batch Name: Batch_1 Unit Procedure: Reaction Batch 1 Start Time: 9/12/04 14:05:00 Unitname: RE105 End Time: 9/12/04 22:07:00 Start time: 9/12/04 14:30:20 End time: 9/12/04 18:23:03 UP1 Operation name: Heat OPN 1 Start time: 9/12/04 14:32:10 End time: 9/12/04 17:32:40 Batch 2 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 Complete electronic batch records

  37. Product Definitions Production Capability Production Schedule Production Performance Detailed Production Scheduling Production Tracking Resource Management (QA) Product Analysis Production Dispatching Historical Data Management Process Analysis Product Definition Management Production Execution Production Analysis 800xA Operations Process Monitoring Automated Control Manual Operations ISA S95.03d Production Control Functions Supply Chain Integration ECS – Enterprise Connectivity Solution 800xA Information Management 800xA Production Management -Batch

  38. Introduction • ECS Framework closesinformation gap between Business processes and the Manufacturing processes (machines, control systems). ECS

  39. 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 =

  40. Levels

  41. ECS Based Connectivity • ECS Makes Business Systems visible to the rest of the 800xA System as just another control equipment Business System 800xA Core 800M Controller

  42. 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

  43. Manufacturing Process Modeling tool (S95) Executable Code Business System1 Business System1 Business Systems Model-based Integration Manufacturing Process Database Devices People (GUI) Manufacturing Process Execution

  44. MES - 95 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 • 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.) Batch production data (consumption, confirmation, quantity produced) BAPIs, RFCs SAP PP-PI SAP Control Recipe 800xA IM ECS 800xA Batch Control System

  45. 2004-04-12 2004-04 2006 2004-12 2005 • 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 segments 17 workshop sessions, 8 months Taskforce results and recommendations presented to management Agreed to continue to concrete actions: Pilot customers Integrated scenarios refined Concrete development ABB CPM Connector for Pulp & Paper ABB ECS framework SAP Connectivity and Netweaver certification Development of the ABB-SAP Joint Solution Task forceresults with recommendations Joint solutiondevelopment Joint solutionready to deploy ABB-SAPCo-operationinitiated ABB-SAPTask force Pulp & Paper Sapphire Paris

  46. 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.

  47. 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 process Data.

  48. SQL / OLE DB / ODBC

  49. MES CRM SCM ERP ECS – Enterprise Connection Solution Services Based Integration Point to Point Interfaces ECSBenefits • Open technology • Reduced risk • No need to rip and replace • Lower TCO with simpler systems Integration Business Solution Business Systems SCM CRM ERP Enterprise Interface xMII Integrated CompositeApplications E Business Legacy Plant Interface ECS Plant Floor Systems ABB and 3rd party control systems, historians and CPM

  50. 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

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