ABB MES AstraZeneca
March 10, 2023 | Author: Anonymous | Category: N/A
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Arto Lind
Industrial IT System 800xA ISA-95/S88 Standards Batch Information Management MES functionality
13 mars 2007
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ISA-95 Perspective on Manufacturing
Business Process transactions y t i l i c a F g n i r u t c a f u n a
ISA-95.01/02
M
Real-Time Control & Events
Business Planning & Supply Chain Mgmt Production Definition
Production Capability
Production Plan
Production Information
Definition Production Management Transactions
Level 4 Timeframe: Months, Timeframe: weeks, days, shifts
ISA-95.05 Functionality
Manufacturing Operations Management
Level 3 Timeframe:: Day Timeframe Da y, Shift, Hour, Minutes, Seconds
ISA-95.03/04 Functionality Continuous
Batch
Discrete
Sensors, Actuators and Logical Devices
Level 0, 1, 2 2 p u o 7 r 1 G t B c B O A 3 2 ©
ABB Coverage
ISA S95 Standard Scope
ENTERPRISE
ISA S88 Standard
95.01 & .02 ISA SITE
Standard
95.03 AREA
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CONTINUOUS PRODUCTION UNIT
AREA
BATCH PROCESS CELL
AREA
DISCRETE PRODUCTION LINE
Enterprise and Control Layers are Merging
1995
1985 Business Planning & Logistics Production Planning ERP
2005
Manufacturing Operations Execution and Control MES
SCADA
CPM Layer * (if existing)
DCS / PLC
Plant Instrumentation and Controls 4 p u o 7 r 1 G t B c B O A 3 2 ©
Extended ERP
Enterprise Layer
Control Layer
n i o t c u d o t r a g t n a n e P i l D d m t e l e u c g i d e u t a h d a n e c o r a D S P M
e c r u o s e t R n n e o i m t e c g u d a o n a r M P
a t a D n o n i o t i c t u c e d l l o r o P c
s i s y t l n a e c n n e A a m t e c n e g u t a n n d i o a a r m M P
g n i k c a r t t c u d o r P
Extended Manufacturing
n o i t i s c s u y l d a o r n P a
Platform for Control and CPM/MES
One common platform for all manufacturing functions
Utilize modular 800xA software functions as required ERP
ISA-95
LIMS/DMS/etc
Specific Adaptors
Web Services
Traditional Interface
Enterprise Connectivity Solutions (ECS) Real-Time Asset Batch Manufacturing Information Production Management Optimization Management Management Intelligence
Common Operations, Engineering, & Data Management 5 p u o 7 r 1 G t B c B O A 3 2 ©
- - - - - - - - - - - - - - - - Real-time Data Sources- - - - - - - - - - - - Blending Granulation Tablet
Coating Other OPC
Enterprise Connectivity Solutions (ECS)
Scope of ISA 95 Part 3 To Define: Activities s of manufacturi manufacturing ng Operations Management Management Activitie
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Terminology and a consistent set of concepts and models for defining manufacturing operation management activities
Interactions between activities
Data that flows among these activities
Production Operations Product definition
Production capability
Production schedule
Production performance
Detailed production scheduling Production resource
Production tracking
management Production Performance analysis
Production dispatching Production data collection
Product definition management Production execution
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Equipment and process specific production rules
Operational commands
Operational responses
Production level 1-2 functions
Equipment and process specific data
ISA S95.03d S95.03d Production Control Functions Product Definitions
Production Capability
Production Schedule
Production Performance
Supply Chain Integration ECS Enterprise Connectivity Solution –
Detailed Production Scheduling
Resource Management
800xA Information
(QA) Product Analysis
Production Dispatching
800xA Production Management -Batch
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Management
Production Tracking
Product Definition
Historical Data
Management
Management Production Execution
Process Monitoring
Process Analysis
Production Analysis Automated Control
Manual Operations
800xA Operations
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 runtime between batches at
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Collecting and storing batch historical information
ISA S88.01 Batch Standard Equipment Hierarchy
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Procedure Hierarchy
Area
Procedure
Process Cell
Unit Procedure
Unit
Operation
Equipment Module
Phase
ISA S88 Procedure Hierarchy Procedure
Unit Procedure
Operation
Production strategy organized by levels
Procedural elements can be used in multiple procedures
An element within within a Procedure Function Function Chart may represent another nested(PFC) Procedure Initialize Unit ready
Phase
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An element within within a PFC may launch and supervise sequential logic in process controller
Inert Pressure Press > target Vent
System 800xA Production Management
Product Definition Management
Procedure Function Chart (PFC) Editor provides a graphical workflow of operations and procedures
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Single masterproduction recipe for automated and manual workflows
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 equipmentand andallocates other resources at run-time based on priority of each batch
Provides views and control of
equipment statusetc.), (Available, Busy,, Reserved, Busy Batch ID, equipment attributes, and reservation queue 3 1 p u o 7 r 1 G t B c B O A 3 2 ©
Single, unified plant object model reduces engineering costs.
System 800xA Production Management
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Production Resource Management
View equipment status (Available, Busy, Busy, Reserved, etc.)
View Batch ID
View and change equipment attributes
View and manipulate reservation queue
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
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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 800xA Production Management
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Production Schedule Interface
Enables 800xA tointerfaces external from applications Examples of actions supported
Scheduling a batch
Retrieving status information
Changing batch state
and parameters Retrieving batch history variables
Create Process
Execute Process
Upload Process
Order
Order
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
Provides complete access to information required for business system integration.
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System 800xA Production Management
Functional Structure and Components Recipes
ERP/MES Applications
Scheduler
Operations Production Orders
Production Reports
Control Recipes Phases
Batch Management Server
Information Management PDL
Control
Procedures Events Operator Comments Batch
Plant Explorer
Operations
Numeric Control
& System Events
Operator
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Control &
Engineering
I/O
Production
Trend Data Actions
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Common Equipment Model of System 800xA Object Type
Functional
Structure
Structure
Equipment Structure
Procedure Structure
Master Recipes 8 1 p u o 7 r 1 G t B c B O A 3
Equipment Unit Types
Instances of Physical Equipment
Groups
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AC800M Controller Integration
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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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System 800xA Production Management
Operator Workplace with Batch
Equipment Overview
Batch Overview
Procedure Function Chart
Process Graphic
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System 800xA Production Management
Flexible Recipe Management
Reusable recipe blocks follow S88building batch control standard
Improves production yields, minimizes scrap, and improves overall production profitability profitability..
Exception procedures provide recipe-driven error handling capability, breakpoints and block skip points
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View current status of recipe procedures and associated standard operating procedure
Supports on-line changes to control recipe without suspending the batch
Procedure Function Chart
Standard Operating Procedure
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Full Support for FDA 21 CFR Part 11
System 800xA provides features across the entire system that facilitate validation
Security – Security – authorization & access control
Configuration change management
Versioning
Synchronization between engineering
& production systems Batch will provide on-line versions for procedures
Audit trail – trail – logging by audit event type
E-signatures & signature/record linking
Record archiving & retrieval
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Reporting - printe Reporting printed d copy of reco records rds for inspection
System checks - device checks and System 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
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Supports LAB data entry Prints reports using third party report builder
Archives data and 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 S95.03d Production Control Functions Product Definitions
Production Capability
Production Schedule
Production Performance
Supply Chain Integration ECS Enterprise Connectivity Solution –
Detailed Production Scheduling Resource Management
Production Tracking (QA) Product Analysis
Production Dispatching
800xA Production Management -Batch
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800xA Information Management
Product Definition
Historical Data
Management
Management Production Execution
Process Monitoring
Process Analysis
Production Analysis Automated Control
Manual Operations
800xA Operations
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Information Management
Production Performance Analyses - Information Management
Desktop, Reporting & Analysis
Information availability
Application
Archiving Engine Control Room
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Process Data
External Production Data (ERP, MES etc..)
Integration
Data Alarm & Event Data
Production Data
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InformIT Information Manager Architecture Information Manager Enterprise Edition Server
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Information Management
Seamless handling of historical data Operator Workplace/Desktop Display
Messages
Real-time and
in the 800xA System
History data in History Server
System alarms/events
50k messages
Audit Trail alarms/events
Seamless view of all data
50k messages
– 12 million messages
1 sec /1 week
- 1sec / 10 years
Process alarms/events
Historical storage
Trend logs in Connectivity Server
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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: Req. max buffer size: Max buffer size:
30.000/min Con.Server: 3 months IM Hist.Server: 10 years
1 sec /1 week Control Network
Archive
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Information Management
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 canned reports that can be used “right out of the Prebox”
B
Campaign
Job Name: Recipe Name:
B at atc h 1
Production Polystyrene grade 4 Polystyrene_A4
Batch Name: Start St art T im ime: e:
Batch 1 9/29/95 14:05:00
End En d T im ime: e: 9/29/95 Unit Procedure: Unit Unit Unitname: Proceedure 1 Start time: End time:
Operation 8 2 p u o 7 r 1 G t B c B O A -
B at at c h 2
Phasename: start: initial temp: target temp: end: final temp:
22:07:25 Reaction Reactor R-105 9/29/95 14:30:20 9/29/95 18:23:03 Heat 9/29/95 14:32:40 23.5 Deg. C 55.0 Deg. C 9/29/95 16:35:12 55.1 Deg. C
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Information Management
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
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Presentation and Navigation
Plant Explorer navigation for Information Manager data
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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
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Information Management
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Web Clients
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Information Management
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Presentation and Navigation
DeskTop Trend
Trend Control
Tag Ticker Ticker
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Softpoints & Calculation exempel Transform data into User-defined data points
actionable information Calculation aspect
Softpoint object Softpoint signals
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Calculation script
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Flexible Reports
Microsoft Excel, Crystal Report
Real time data, historical, lab data, dat a, batchbatch- and event event-information
Report Rep ort genera generatio tion n
Printer
Email
Historical archiving LolalLola l- or netw network-d ork-disc isc
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Flexible Report generation & distribution
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Security
Secure Data Security in Pharmaceutical Pharmaceutical Industry
Secure historical data storage
Archival/retrieval from external media
CD, DVD, Magneto Optical
Remote disk location
Direct data read of archived tag
Archive
based on production event such as batch end
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Distributed data storage Secure report storage Disk arrays
User access control
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System 800xA Information Management
Production Data Collection / Tracking Camp1
Campaign Name: Intermediate_S7_2004AXH Recipe Name: Int_S7_Std Batch Name: Start Time: End Time:
Batch 1
Unit Procedure: Unitname: Start time: End time:
UP1
OPN 1
Batch 2
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Batch_1 9/12/04 9/12/04
14:05:00 22:07:00 Reaction RE105 9/1 9/12/04 2/04 14:3 14:30 0:20 :20 9/1 9/12/04 2/04 18:2 18:23 3:03 :03
Operation name: Heat Start time: 9/12/04
14:32:10
End time:
17:32:40
9/12/04
Single common storage of batch record Data batchstored recipeaccording structure to All batch events, operator actions, system events, process alarms and events are stored
Complete electronic
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batch records
ISA S95.03d S95.03d Production Control Functions Product Definitions
Production Capability
Production Schedule
Production Performance
Supply Chain Integration ECS Enterprise Connectivity Solution –
Detailed Production Scheduling Resource Management
Production Tracking (QA) Product Analysis
Production Dispatching Product Definition
Historical Data
Management
Management
800xA Production Management -Batch
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u o r 7 1 G t B c B
800xA Information Management
Production Execution Process Monitoring
Process Analysis
Production Analysis Automated Control
Manual Operations
800xA Operations
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Introduction
ECS Framework Framework closes inform information ation gap between between Business Business processes and the Manufacturing processes (machines, control systems).
ECS
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Functionality
BRIDGE BETWEEN PLANT FLOOR CONTROL SYSTEMS AND ENTERPRISE BUSINESS SYSTEMS
ENHANCEMENT
MANUFACTURING MANUFACTURI NG VISIBILITY - EFFICIENCY ISSUES, PRODUCTIVITY ISSUES, AND QUALITY
ECS = ECS =
OF RESPONSIVENESS TO BUSINESS DECISIONS
ISSUES IN CONTEXT
PRODUCTION REALITY
QUALITY DATA MANAGEMENT - RE RECO COGNI GNISE SE
PLAN, RESPOND AND CHANGE ON DEMAND; NO MORE GUESSING –
AND RESPOND TO QUALITY CHALLENGES 9 3 p u o r 7 1 G t B c B
EVOLUTIONARY APPROACH - CO CONTI NTINU NUOU OUS S IMPROVEMENT
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Levels
Applied Manufacturing Framework
Manufacturing Framework
IT Framework
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800xA Core Platform
Factory and domain specific deployments
Methodology and for modeling and implementation oftools solutions for different factories and manufacturing domains.
Reusable software components, fully integrated in 800xA Core Platform
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ECS Based Connectivity
ECS Makes Business Systems visible to the rest of the 800xA System as just another control equipment Business System
800xA Core 1 4 p u o r 7 1 G t B c
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 Execution Manufacturing Process Modeling tool (S95)
Executable Code
Business Business System1 Business System1 Systems
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Manufacturing Process Database
Model-based Integration
Devices People (GUI)
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MES
ECS- Enterp Enterprise rise Conne Connection ction Solut Solution ion
Configurable connectivity to various business systems (e.g. SAP)
including BAANconnector or any ERP from SSA Global Tracking & Traceability, Reports, Database Based on
Case: SAP PPPI
- 95 –
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, i ngredient, produced material quantity, quantity, Phase confirmation and report of used machine and total production time etc.) Batch production data (consumption, confirmation, quantity produced) BAPIs, RFCs SAP Control Recipe
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800xA IM
800xA Batch
Control System
ECS
SAP PP-PI
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Development of the ABB-SAP Joint Solution ABB-SAP Co-operation initiated 2004-04
ABB-SAP Task force Pulp & Paper
Task force results with recommendations
Joint solution development
2004-04-12
2004-12
2005
Joint solution ready to deploy 2006
Sapphire Paris Initial industry: Pulp Detailed & Paper analysis of production business processes of various P&P to Concrete development Taskforce Taskfo rceand results and recommendations presented Taskforce Charter: industry segments ABB CPM Connector for Pulp & Paper management 17 workshop sessions, 8 months ABB ECS framework Define appropriate customer segmentationAgreed (products, regions,…) to continue to concrete actions: SAP Connectivity and Netweaver Identify pain points of the different customer groups certification Pilot customers Linerboard Example Forecast or
Integrated scenarios Determine theresolution are pain points which are significant and refined where we can find/have awhere combined Replenishment
Customer Order Entry
ATP Check
N
CTP Check
Prod. Plan. Winder
Prod. Plan Paper Mach.
Planning Pulp
ECS – Overview
Evt. stock transfer order from box plant VMI
Identify value proposition (quantifiable) for IT and Organizational Pain Points Customer In operation since 2004 in ABB’s ABB Circuit Breaker plant in Dalmine, SAP •
•
Retrim Reallocation
Detail Scheduling Pulp
Merger / Divestment
Confirmation Roll
Transport. Planning
Confirmation How to facilitate easy integration in merger/divestment cases: anew mill Jumbo
Middleware
to integrate„Mother in anReel existing corporate system; an existing mill to de-couple and join Registration “ another company
„ReelRegistration“
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9 3 / e c r o F
k s a T B B A P A S , 4 0 0 2 G A P A S / y O B B A
Billing / Invoicing
Delivery
WM
Standardised ERP & MES products rolled out in parallel
Tracking
QM
System architecture
Define possible integration scenarios
Italy
AnyRDBMS
Database
Based on
If more and more tasks are moved into a central planning system, it has to be assured by - 95 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 architecture provides a unbreakable data flow that the technical system
Costing (FI, CO/PA)
Describe potential partnership scenarios
.NET technology
Warehouse management:
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k s a T B B A P A S , 4 0 0
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 3 inventoryvaluation? B B
Database
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0 2 G A P A S / y O B B A
A r a e y t h g i r y p o C ©
ABB CPM
Devices
ABB Historian ABB Controls 3rd party Historian
3rd party controls
Connecting to SAP – 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 – 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.
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B O A 3 © 2
SQL / OLE DB / ODBC
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c B O A 3 © 2
MES
ECS – Enterprise Connection Solution
Point to Point
Services Based
Interfaces
Integration Business Solution
Business Systems SCM
CRM
ERP
CRM SCM
ERP
xMII
E Business
Legacy
Open technology
Reduced risk
No need to rip and
Enterprise Interface
Integrated Composite Applications
Plant Interface
ECS
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ECS EC S Bene Benefi fits ts
Plant Floor Systems ABB and 3rd party control systems, historians and CPM
replace Lower TCO with simpler systems Integration
c B O A 3 © 2
Indus Ind ustria triall IT - Sum Summar mary y
800xA includes a very comprehensive flexible batch solution
Information Management as info system with excellent reporting and analyses tools
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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
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products
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