“Standards for Shop-floor

Information Systems”

Asish Adhikari
Tata Consultancy Services Ltd.
Agenda

Evolution of Shop-floor Information Systems Space

Constituents of Shop-floor Operations & MESA

Integration & Shop-floor Operations

Standards for Shop-floor Information Systems

How to use standards for Shop-floor Information

Systems

Summary

Q&A

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Evolution of the Enterprise

Strategies and
competitive priorities
leads to decision for
making Products
STRATEGY

Products planning leads
PLANNING to Process, Technology,
Layout, Location and
EXECUTION
Capacity
CONTROL
Choosing a Technology
leads to basic control &
Functions across an Enterprise
automation for the
Layout

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Evolution of Shop-floor Information
Systems space

Execution & control functions account for 70-85% of

the total cycle time of manufacturing

The execution functions were mostly met through
bespoke applications or manually

Even with right strategies and optimized planning,
enterprises were pressed hard to cope up with the
requirement of “The Right product at the Right time at
the Right Price”

The need to be globally competitive and stay adaptive

created the space for Shop-floor Information Systems
to flourish

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Constituents of Shop-floor Operations

Shop-floor Activities of
Operations Individual
Management Operations

Detail Scheduling

Production
Resource Management

Definition Management

Maintenance

Lot / Batch Management

Process Execution

Quality

Product History

Data Collection

Inventory

Analysis
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MESA – A step to define the Shop-floor
space

A non-profit organization formed by leading

manufacturing execution software vendors in 1992,
provided a forum for competitors to work together to
expand awareness and use of manufacturing
technology

Defined a set of 11 functionalities that should ideally

be part of shop-floor operations and thus need to be
addressed by shop-floor information systems

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MESA Model

Sales &
Service
Management Enterprise
Resources
Supply Chain Planning
Operations/ Resource
Management Detailed Allocation
Scheduling & Status

Document
Dispatching MES Control
Production
Units
Product Performance Product /
Tracking & Analysis Process
Genealogy Engineering

Labor Process
Management Maintenance Management
Management

Data
Controls
Quality
Collection
Management
Acquisition

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The need to Integrate
Visualize & Re-align

Business Planning
Plant Production Scheduling,
Operational Management, etc
STRATEGY

Contextualize, Analyze & Propagate

PLANNING Manufacturing
Operations
Dispatching Production, Detailed Production
EXECUTION
Scheduling, Process Management, ...

Aggregate

CONTROL
Batch Continuous Discrete
Control Control Control

The nature of execution functions necessitated the need for Integration

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The Challenge to Integrate

Functionality overlap

Too huge and diverse portfolio to address
• Definition Management
• Data Management

Dissimilar nature of operations
• Necessity for horizontal as well as vertical
integration

Dissimilar nature of applications
• Custom developed
• Legacy applications
Requirement of Standards originated from the diversity…..
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Standards for the Shop-floor Information
Systems

Instruments Society of America (ISA)

• S88, S95

World Batch Forum (WBF)
• Batch ML, B2MML

Open Applications Group (OAGi)
• OAGIS XML, BODs

Machinery Information Management Open
Systems Alliance (MIMOSA)
• OSA – EAI, OSA- CBM, Open O&M

OLE for Process Control (OPC)
• OPC-UA

Too many Standards led to the confusion….

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Collaboration between different Bodies

OMAC User Group

• Packaging Machinery, Manufacturing
Infrastructure, and Machine Tool

Operations & Maintenance
• OPC & MIMOSA

Manufacturing Interoperability Guideline
Working Group
• ISA, WBF, MIMOSA, OAG, OPC

Even after consolidation it is not clear how to use them….

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Varied approaches for the Shop-floor
Information space

ERP vendors approached the space with the

advantage of having similar data models…

Automation vendor approached the space
with the advantage of capturing real-time
data…

Niche IT players and some automation
vendors approached the space with the
advantage of providing a framework with
standard programming languages

Confirmation to standards varied from vendor to vendor and

the way they defined them….
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The “Typical” thought…

For enterprises, business process is

paramount. It tends to not care about what IT
application enables it, as long as they perform
to the SLA’s defined by their customers

Information systems should lead to “Self-
Optimizing Enterprises responding smartly to
the market dynamics”

Information Systems

Business Optimize Technology Enable extended

Convergence Investments Enterprise

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Framework for Shop-floor Information
Systems

Shop-floor IS
Requirement

Functional Technical

Requirement Functional Solution Deployment

Process Mapping Data Models
Mapping Architecture Architecture Architecture

“Clear articulation of functional and technical specification is

possible through use of standards”
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Use standards for modeling the
Requirements

Standard based Approach

Business Convergence

Capturing Problem Domain Knowledge

 Functional Requirements S88, S95 Part 3,

 Functional Architecture IDEF, UML, MESA

Analysis Design Development

Optimize technology

Defining Optimal IT Solution

 Technical Architecture S95 Part 1 & 2,

 Deployment Architecture OAGi, OPC,
MIMOSA, WBF
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Benefits of using Standards

Enhanced process efficiency

• Business processes are mapped
• Traceability of requirements to deployment
architecture
• Increased automation of work-flow

Standard driven initiative gives a modular
and scalable architecture
• Fewer Interfaces
• Less effort for enhancements
• Lower cost of maintenance
• Lower cost of compliance

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Summary

Shop-floor Information systems may be very

easy to talk about, but you need a strong
strategy in place to implement it

Make use of standards, they are there to help
you

It is worth investing in a System Integrator
to do the job for you
• COTS package knowledge
• Knowledge of Standards
• Integration tool expertise

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Q&A

For more information, contact at

[email protected]

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Thank You

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