ABB MES AstraZeneca

March 10, 2023 | Author: Anonymous | Category: N/A
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Description

 

 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

      1    1     p   u   o   7   r    1    G      t    B  c    B   O    A     3    2    ©

 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.

   ©      

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

     7    1 DDRIVE   (123)   p RCM  AO (29) (62)   u (68)   o   7   r  AO (29)    1    G (68)      t    B  c    B   O    A     3

Control &

Engineering

I/O

Production

Trend Data Actions

   ©    2  

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

   ©    2  

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.)

   ©    2  

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

   ©    2  

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

   ©    2  

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.

   ©    2  

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

       ©    2  

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

   3    ©    2  

InformIT Information Manager Architecture Information Manager  Enterprise Edition Server 

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   3    ©    2  

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

   3    ©    2  

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

   3    ©    2  

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

   A    3    ©    2  

Information Management

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Web Clients

   A    3    ©    2  

Information Management



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Presentation and Navigation

DeskTop Trend 

Trend Control



Tag Ticker  Ticker 

   A     3    ©    2  

Softpoints & Calculation exempel Transform data into User-defined data points

actionable information Calculation aspect

Softpoint object Softpoint signals

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Calculation script

   A     3    ©    2  

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

   A     3    ©    2  

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

   A     3    ©    2  

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





     6    3     p   u   o   r    7    1    G      t    B  c    B O

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

       A     3    ©    2

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

     7    3     p

  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

   O    A     3    ©    2  

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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   O    A     3    ©    2  

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

   O    A     3    ©    2  

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 

       O    A     3    ©    2  

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 

   B   O    A     3    ©    2  

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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   B   O    A     3    ©    2  

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)

   B   O    A     3    ©    2  

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

   B   O    A     3    ©    2  

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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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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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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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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SQL / OLE DB / ODBC

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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

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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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