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

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.

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ISBN-13: 978-0-9792343-8-5

ISBN-10: 0-9792343-8-7

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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

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 step-by-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 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

About the Author

Bianca Scholten is a principal at Accenture, a global management consulting, technology services and outsourcing company, with more than 223,000 people serving clients in more than 120 countries. She advises multi-nationals on the definition and realization of their manufacturing IT strategies. She is a voting member of the ISA95 committee. Ms. Scholten is also the author of the book MES Guide for Executives: Why and How to Select, Implement and Maintain a Manufacturing Execution System, for which she received the Thomas G. Fisher award (best new standards-based ISA book of 2009) and the Raymond D. Molloy award (best-selling ISA book of 2009). Two years earlier she already won the 2007 versions of these same awards for The Road to Integration. Ms. Scholten received the ISA Standards and Practices Award for her outstanding contribution to the technical report Using ISA-88 and ISA-95 Together. She has published many papers in trade journals on subjects related to vertical integration and technical automation and has trained hundreds of professionals in applying the ISA-88 and ISA-95 standards.

Table of Contents

Introduction

Chapter 1: Getting Acquainted with ISA-95

1.1Introduction

1.2History of the Development of ISA-95

1.3Objective and Content of ISA-95

1.3.1Part 1

1.3.2Part 2

1.3.3Part 3

1.3.4Part 4

1.3.5Part 5

1.4Opportunities for Applying ISA-95

1.4.1ISA-95 as an Analysis Tool

1.4.2ISA-95 Applied to the Development of MES Applications

1.4.3ISA-95 Applied for Vertical Integration

1.5Advantages of Applying ISA-95

1.6The SP95 Committee

1.7The ISA-95 Hype

1.8The Future of (and with) ISA-95

1.9Summary

Notes

Chapter 2: Applying ISA-95 as an Analysis Tool

2.1Introduction

2.2Why Perform an ISA-95 Analysis?

2.3The Steps in an ISA-95 Analysis

2.4Preparation and Methodology

2.4.1Written Input or Interviews?

2.4.2Determine the Scope

2.4.3Select Employees for Interviews

2.4.4Schedule the Steps of the ISA-95 Analysis

2.4.5Prepare to Conduct the Interview Sessions

2.4.6Process the Information

2.4.7The Analysis Deliverables

2.5Getting Down to Work

2.5.1Step 1: A Tour of the Company

2.5.2Step 2: Determine the Scope and the Business Drivers

2.5.3Step 3: The Functional Hierarchy Model

2.5.4Step 4: The Equipment Hierarchy Model and Process Segments

2.5.5Step 5: The Functional Enterprise-Control Model

2.5.6Step 6: The Production Operations Management Activity Model

2.5.7Step 7: The Maintenance Operations Management Activity Model

2.5.8Step 8: The Quality Test Operations Management Activity Model

2.5.9Step 9: The Inventory Operations Management Activity Model

2.5.10Step 10: Other Activities Important on Level 3

2.6Writing the Conclusion and Recommendations

2.6.1Summary of the Most Important Findings and Points of Concern

2.6.2A Proposal for the Follow-up Trajectory

2.6.3Points of Concern for the Follow-Up Trajectory

2.7Points of Concern in an ISA-95 Analysis

2.7.1Pitfalls during the Preparatory Phase

2.7.2Pitfalls during the Interview Sessions

2.7.3Pitfalls during the Processing Phase

2.7.4Pitfalls during the Conclusion

2.7.5General Pitfalls

2.7.6Summary

2.8End Users’ Experiences with ISA-95 Analyses

2.8.1Aviko’s Investigation into SAP and MES

2.8.2Abbotts Investigation into Electronic Batch Records

2.9Summary

Notes

Chapter 3: Understanding and Applying the ISA-95 Object Models

3.1Introduction

3.2Object Models: The How and Why

3.3General Description of the Object Models

3.3.1From Thirty-one Information Flows to Nine Object Models

3.3.2UML Models

3.3.3Tables, Attributes, and Properties

3.3.4IDs

3.4Example: That’s Y Furniture

3.5The Resource Models

3.5.1Personnel

3.5.2Equipment

3.5.3Material

3.5.4Process Segment

3.6The Remaining Models

3.6.1Production Capability

3.6.2Product Definition Information

3.6.3Production Schedule

3.6.4Production Performance

3.7Other Points of Concern

3.7.1UML Classes and ISA-95 Objects

3.7.2ISA-88 or ISA-95?

3.8Case Study

3.8.1Logistics or Production?

3.8.2The ISA-95 Configuration

3.8.3Specific Scheduling Problems and Their Solutions

3.8.4Using the Application in Other Enterprises

3.9Summary

Notes

Chapter 4: Applying ISA-95 to Vertical Integration

4.1Introduction

4.2Integration Theories

4.2.1What is Vertical Integration?

4.2.2Why Integrate Vertically? Why Standardize?

4.3The ISA-95 Integration Architecture

4.3.1Introduction

4.3.2XML and B2MML

4.3.3Middleware

4.3.4Adapters

4.3.5The Role of ISA-95 Part 5 in the Integration Architecture

4.4Integration of Enterprise and Control Systems Using ISA-95

4.4.1Step-by-Step Plan

4.4.2Subsequent Phases in the Integration Project

4.5Points of Concern

4.5.1Master Data Management

4.5.2Who’s the Owner?

4.5.3Status of B2MML Support among ERP and MES Vendors

4.5.4The Status of B2MML

4.6Summary

Notes

Glossary

Appendix

Bibliography

Introduction

Introduction

When I began giving ISA-95 trainings around 2001, there was almost no information available about the standard. There were also practically no plants or system integrators who had any experience with it. Since then the situation has changed appreciably. Various companies worldwide have completed ISA-95 projects. Whitepapers have been written - I’ve written several articles for Dutch trade journals myself - companies have shared their experiences at conferences and exhibitions, and training institutes now offer courses. But there’s still no book. No book for someone to read who hasn’t taken a course, hasn’t read any articles, and hasn’t got any basic knowledge of the standard. No book that not only explains the basic principles of ISA-95, but also presents different companies’ experiences and implementation methods. No book that offers something more to hold on to for people who do already use the standard in daily practice. It seems to me it’s time to bring such a book to market.

I’ve written this book for people - end users, consultants, and system integrators, among others - who are involved in automating MES activities and the exchange of information between MES systems and ERP systems. You don’t need any background knowledge of ISA-95 to understand the book. Chapter 1 explains the most important ISA-95 models and terminology and provides background information about the standard. I wrote this book not only for beginners, however, but also for people who already have some practical experience with ISA-95, perhaps as a consultant, project manager, programmer, or information architect. Chapter 2 offers consultants and project managers additional support in carrying out ISA-95 analyses to determine a specific company’s MES strategy and to define user requirements. Chapter 3 helps people who develop MES functionality or realize interfaces based on ISA-95 to understand and apply the ISA-95 object models. (If you just want an overall understanding of ISA-95, you can skip chapter 3.) Finally, chapter 4 explains how to integrate ERP and MES systems using ISA-95. It places ISA-95 in the broader context of modern information exchange technologies and thus offers a complete picture for project managers, consultants, programmers, and information architects who want to integrate ERP and MES systems based on the international standard. Chapters 2, 3, and 4 can be understood by anyone who’s acquired a basic knowledge of ISA-95, for example by reading chapter 1 of this book. You can read this book without having access to the standard. To implement ISA-95 in practice, however, you will need to consult the various parts of the standard. Consider ISA-95 as a kind of encyclopedia. It’s not something you’re going to know by heart after a while. You’ll keep going back to it, time after time, as a reference work. Presuming the reader works in the field of industrial automation, I have assumed that a number of abbreviations in the text are familiar, such as APS, ANSI, CIM, DCS, ERP, MES, MRP I and II, PCS, P&ID, PLC, SCADA, and SOP. Consult the glossary for an explanation of these and other abbreviations. The appendix answers questions such as How can I become a member of the SP95 committee? and Which organizations and websites can keep me informed about the latest developments concerning ISA-95?

Finally, I make grateful use of the opportunity to point out to universities and trade schools the value of ISA-95 for educational objectives. ISA-95 offers a fundamental understanding of the activities and information flows within manufacturing companies, and is thus an outstanding way to familiarize newcomers with the ins and outs of industrial companies.

All that remains is for me to thank several people and organizations. Their efforts and assistance have helped to make the publication of this book possible. First, of course, my thanks to the ISA organization, the SP95 committee members, WBF and the B2MML working group members, without whose immeasurable, strings-free input the standard and B2MML would not even exist. Second, thanks to Rob Hulsebos, Nicole Delissen and Jaco Otto for their valuable advice. Thanks also to all my interviewees for their stories from the field. Next come several of my valued and capable colleagues at Ordina: Peter Bierens, Ton Bogerd, Hans Bogers, Marc van de Langenberg, Art Ligthart, Bettina Logge, and Nick van der Schilden. Thank you for your critical comments, tips, and other assistance. They have greatly contributed to the quality of this book. And thanks to the Columbian student Libardo Steven Muñoz Trochez, whose questions provided insight into what people need to know about ISA-95 during different phases in their acquisition of knowledge and experience. Thank you, Jean Sassi, for your valuable support in writing several complex sections. Last but not least, thanks again to Jean, and to my family and my friends, who ensured that there was - in addition to writing this book - so much more to enjoy!

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