Practical 

Applications of 
the ISA 95 standard

Dennis Brandl
BR&L Consulting

M ESA KNOWS
SUSTAINABILITY & ECO‐EFFICIENCY ‐ LEAN ‐ METRICS & PERFORMANCE MANAGEMENT
INFORMATION INTEGRATION ‐ SAFETY ‐ ASSET PERFORMANCE MANAGEMENT ‐ B2MML
QUALITY & COMPLIANCE ‐ PRODUCT LIFECYCLE MANAGEMENT ‐ AUTOMATION

Do you know M ESA?
 Dennis Brandl
• Dennis Brandl has been an active member of ISA’s SP88 
y
Batch Control System committee since 1990, a U.S. 
expert in batch control to IEC,  editor of the ISA95 
Enterprise‐Control System Integration standard, and 
convener of the IEC SC65E JWG 5 working group.  
• He has been involved in automation system design and
He has been involved in automation system design and 
implementation for the past 30 years including Apollo 
and Space Shuttle test systems for Rockwell Space 
Division, as well as work with Shell Oil, Texas 
Instruments, Siemens, Square D, Sequencia,
Instruments, Siemens, Square D, Sequencia, 
Telemecanique, Modicon, Pfizer, Lilly, Merck, GSK, 
Genentech, P&G, DOW, and other process industry 
companies.
• Dennis has a B S in Physics an M S in Measurement
Dennis has a B.S. in Physics, an M.S. in Measurement 
and Control from Carnegie Mellon University, and an 
M.S. in Computer Science from California State 
University. 

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Agenda
• Introduction to ISA 95 & MES
• Advantages of the ISA95 standard
• Most important models of ISA95
Most important models of ISA95
• Practical applicability of the ISA95 models for 
end users, consultants and engineers
d lt t d i
• Practical examples and descriptions of typical 
application structures
• Questions and answers

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 What is ISA 95
• USA ANSI standard developed by an ISA Committee of volunteer experts

• ANSI/ISA 95.01 ed2 “Enterprise ‐ Control System Integration –
Part 1: Models and Terminology”
• ANSI‐ISA 95.02 ed2 “Enterprise ‐ Control System Integration –
P t 2 Obj t
Part 2: Objects and Attributes”
d Att ib t ”
• ANSI/ISA 95.03 ed2 “Enterprise ‐ Control System Integration –
Part 3: Models of Manufacturing Operations” 
• ANSI/ISA 95.04 ed1  Enterprise ‐ Control System Integration 
ANSI/ISA 95.04 ed1 “Enterprise Control System Integration –
Part 4: Objects and attributes for manufacturing operations management 
integration”
• ANSI/ISA 95.05 ed3 “Enterprise ‐ Control System Integration –
Business to Manufacturing Transactions
Business to Manufacturing Transactions

• Also available as IEC/ISO 62264 standards

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 A Bit Of History
• Prior to ISA 95 
– MES was not a well defined area, slow growth in deployments
MES was not a well defined area slow growth in deployments
– MES was sometime viewed as a solution in search of a problem
– Hard to integrate with business level systems and shop floor control
– Very, very, very industry specific 
y, y, y y p
– No common definitions or terminology
• After ISA 95 
– Redefined MES as MOM (Manufacturing Operation Management)
– MOM activities are well defined
– Standard definitions and terminology, common requirements
– Well understood and supported business level to ship floor control 
i t
integration
ti
– More cross‐industry solutions becoming available
– Significant competition and advances in solutions
– Rapid growth in deployments
Rapid growth in deployments

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Example Benefits from MES/MOM*
Benefit Category  Range of Benefits  Reduction Range

Document Review Approval (SOPs) 
i l (SO ) $ 00 000 $3 Million 
$100,000 ‐ $3 illi 10% ‐
0% 80%

Batch Record Preparation & Handling  $11,000 ‐ $1.3 Million  40% ‐ 80%

Batch Record Review  $115,000 ‐ $1.0 Million 40% ‐ 80%

Data Entry & Calculations  $20,000 ‐ $4.6 Million  40% ‐ 90%

Deviations $6,000 ‐ $1.3 Million  25% ‐ 60%

Logbook Handling
Logbook Handling  $7,000 – $105,000 
$7,000  $105,000 25% ‐ 80%
25% 

Material Losses  Value of preventable discards  30% ‐ 60%

Testing  Preventable deviations testing  30% ‐ 50%

Inventory Carrying Costs  Reduced Inventory Carrying 

Throughput $value of additional batches

RANGE OF TOTAL ANNUAL BENEFITS  $450,000 ‐ >$10 Million

*  CBINet Conference, INDUSTRY BEST PRACTICES FOR MES ARCHITECTURE, August 2009, Key Considerations for 
MES Project Planning and Execution, Michalle Adkins and Paul Brandenburg (Lilly)

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 The Advantages of the ISA 95 Standard 
• Common terminology and definition of functions
– Simplifies writing requirements for end‐users 
Simplifies writing requirements for end users
– Simplified vendor understanding of end‐user requirements
• Integration of ERP with MES/MOM systems
– Prior to ISA 95, projects took 1‐2 years & <50% successful
i j k & % f l
– After ISA 95, projects take 2‐4 months & >90% successful
• Definition of MES/MOM systems
– Prior to ISA 95, specification took years to reach agreement
– After ISA 95, typical specifications complete in < 6 months
– Possible to compare different vendor solutions
• Better match to requirements
– Possible to compare different facilities

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Most Important ISA 95 
Models

M ESA KNOWS
SUSTAINABILITY & ECO‐EFFICIENCY ‐ LEAN ‐ METRICS & PERFORMANCE MANAGEMENT
INFORMATION INTEGRATION ‐ SAFETY ‐ ASSET PERFORMANCE MANAGEMENT ‐ B2MML
QUALITY & COMPLIANCE ‐ PRODUCT LIFECYCLE MANAGEMENT ‐ AUTOMATION

Do you know M ESA?
 Levels and Functions
Level 4 4 - Establishing the basic plant schedule -
Business Planning  production, material use, delivery, and shipping.
Determiningg inventory
y levels.
& Logistics
& Logistics
Plant Production Scheduling, Time Frame
Operational Management, etc
Months, weeks, days, shifts

Level 3
3 - Work flow / recipe control to produce the
Manufacturing  desired end products. Maintaining records and
optimizing the production process.
Operations Management
Dispatching Production, Detailed Production
Time Frame
Scheduling, Reliability Assurance, ...
Shifts, hours, minutes, seconds

Level 2
Level 2 2 - Monitoring, supervisory control and automated
Manufacturing Control control of the production process
Basic Control, Supervisory Control,
Level 1 Process Sensing, Process Manipulation,… 1 - Sensing the production process, manipulating
the production process

Level 0 Production Process 0 - The physical production process

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 ISA95 Domain Definitions
• Provides a method to answer the question;

“What is in logistics 
and 
what is in operations ?“
p

• What is in Level 4 or Level 1‐2‐3?
Wh t i i L l 4 L l 1 2 3?

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Criteria for Level 3,2,1
• Activities to be included in Level 3, 2, or 1 are directly involved in 
manufacturing and includes information about personnel,
manufacturing and includes information about personnel, 
equipment, or material and meets any of the following conditions. 
– The activity is critical to plant safety.
– The activity is critical to plant reliability.
– The activity is critical to plant efficiency.
• NOTE: Absolute plant efficiencies may be dependent upon factors that are outside the control of a facility (MRP 
schedules, product mixes, etc.). 
– The activity is critical to product quality.
– The activity is critical to maintaining regulatory compliance.
Th ti it i iti l t i t i i l t li
• EXAMPLE: Maintaining regional, government and other agency compliance related to products and production. 
• NOTE: This includes such factors as safety, environmental and cGMP (current good manufacturing practices) compliance.

– NOTE: There are other criteria such as company policy and organizational structure, or the nature of the operations that could 
expand the scope of manufacturing operations management
expand the scope of manufacturing operations management. 
– NOTE: Such activities as personnel management of salaries and job titles may be important for running a manufacturing 
business, but they are not considered part of manufacturing operations management. 

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Level Overlap with Systems
Level 4 4 - Establishing the basic plant schedule -
Business Planning  production, material use, delivery, and shipping.
Busine ss Logist ic s Determining inventory levels.
& Logistics
S Production
Syst
Plant t e m sScheduling,
(ERP) Time Frame
Operational Management, etc
Months, weeks, days, shifts

Level 3
Level 3
3 - Work flow / recipe control to produce the
M a nufa c tManufacturing 
uring Ope rat ions desired end products. Maintaining records and
optimizing the production process.
Operations Management
M a na ge m e nt Syst e m
Dispatching Production, Detailed Production
s
Time Frame
(M ES, Bat ch, LI M S, AM , Shifts,
Scheduling, Reliability Assurance, ...
…) hours, minutes, seconds
Cont rol Syst e m s
Level 2 (PLC, DCS, OCS, …) 2 - Monitoring,
g supervisory
p y control and automated
Manufacturing Control control of the production process
Basic Control, Supervisory Control,
I nt e llige nt devic e s
Level 1 Process Sensing, Process Manipulation,… 1 - Sensing the production process, manipulating
(V ision, Flow, … the production process

Level 0 Bat ch, Production Process

Disc re t e , Cont inuous0 - The physical production process

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 ISA 95 Formal Models
• Interfaces to business systems (ERP, MDM, PLM) through XML 
d WBF B2MML S d d (
and WBF B2MML Standard (www.wbf.org)bf )
• Standard model for MOM tasks and activities

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Process Segments
• Defines the Business View of production
Pharmaceutical Manufacturing Example
(3 Segments)

Make
Make Package
Active
Raw Pills Doses Finished
Materials Ingredient
g
P d t
Products

Inventory tracked Inventory tracked Inventory tracked

for Active
Acti e Ingredient for Pills for Pill Packs

Know throughput, Know throughput, Know throughput,

resources and time to resources and time to resources and time to
make Active Ingredient make Pills make Pill Packs

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Integration Models
Integration Models

M ESA KNOWS
SUSTAINABILITY & ECO‐EFFICIENCY ‐ LEAN ‐ METRICS & PERFORMANCE MANAGEMENT
INFORMATION INTEGRATION ‐ SAFETY ‐ ASSET PERFORMANCE MANAGEMENT ‐ B2MML
QUALITY & COMPLIANCE ‐ PRODUCT LIFECYCLE MANAGEMENT ‐ AUTOMATION

Do you know M ESA?
 Enterprise Integration – ISA 95 & 
B2MML
• Integration of business systems to shop floor 
systems is an important final phase in an ERP
systems is an important final phase in an ERP 
implementation
– Companies are discovering that the true value in a 
p g
logistics system only comes when it is connected to 
real world shop floor information.  
• The
The ISA 95 and IEC 62264 standards define the 
ISA 95 and IEC 62264 standards define the
standard terminology for business to 
manufacturing integration
• The WBF B2MML (Business to Manufacturing 
Markup Language) defines an implementation 
emerging as the preferred integration method
emerging as the preferred integration method 

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 How Does ISA 95 & B2MML Help?
• ISA 95 Part 1, Part 2, and Part 5
– Provides a clear description of exchanged information
Provides a clear description of exchanged information
• Does not use vendor specific terminology
– Each piece of exchanged information has an unambiguous 
meaning
• Uses a “Property” model to describe company specific exchange 
information 
– Allows separation of business processes from manufacturing 
processes
• Allows changes in production processes without requiring 
unnecessary changes to scheduling and logistics processes
• B2MML
– Defines an implementation of the ISA models in an XML format
– Defines a standard language for representing exchanged 
information

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 ISA 95 & B2MML Data Models
Is assembled from

Is assembled from Is assembled from Is assembled from

0..n 0..n 0..n 0..n 0..n 0..n

Defines
0..n Made up o f
Material a gro uping Material Material
Material Lot
Class 0..n 0..n Definition 1..1 Defined by 0..n Sublot

0 n
0..n
Has Has Is tested Has
pro perties pro perties Is tested values for Has
by a > by a > values fo r
of Is tested of May be made up
by a > 0..n 0..n of sublots
0..n
Material Test
0..n Specification
Is tested Records the
0..n 0..n execution of
by a > Defines a QA Test
Is tested
by a > procedure Result
fo r
0..n 0..n 0..n obtaining a 0..n
Material Material 0..n 0..n 0..n
Material Lot
Class Definition
May Maps to Property
Property Property
map to

0..n 0..n 0..n

< may co ntain nested < may con tain nested < may co ntain n ested

Attribute Description Production Maintenance Quality Inventory

Name Examples Examples Examples Examples

ID A unique identification of a Polymer sheet 200 cP Oil RH5510 20 mil

specific material class, within the stock 1001A (SAE 90) Wrap
scope of the information
exchanged (production capability,
production schedule, production
performance, …)
Description Additional information about the Solid polymer Very High Oxidizing Wrap used
material class. resin Viscosity Agent to wrap
Lubricating pallets
Oil
Assembly Optional: Defines the type of the Physical Physical Logical Physical
Type assembly
assembly.

Assembly Optional: Defines the type of the Permanent Transient Permanent Transient
Relationship relationships
.

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 Exchanged Level 3‐4 Information
Enterprise Information
Plant Production Scheduling,
Operational Management, etc
Resource
Information Operations Operations Operations Operations
(Personnel,  Capability Definition
Equipment,
Schedule Performance
Physical Asset, Information Information (What to make  (What was made 
(What is available
(What is available (How to make
(How to make and what
and what  and what was
and what was
M
Material
Material,
i l
for use) a product) to use) used)
Segments)

Manufacturing
Control Information
Control Information
Area Supervision, Production Planning, 
Reliability, Assurance, etc

Most Used
Exchanges Today
Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Material Information
• What is shared
• Material Master & Material Inventory information
Material Class Material Definition Lot Sublot
HCl A
Acid
id HCl 50% HCL 50 100019
HCL-50-100019 HCL 50 100019
HCL-50-100019
Barrel 15

pH Density Color Purity Material Test Material Test L

Location
i
Results Specification

pH Density Color Purity

7.0 1.05 Straw 99.5%
Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Material Information
• Material Master 
– Represented in “Material Definition” & “Material 
d “ l f ”&“ l
Class”
– Usually sent from ERP (SAP) to MOM systems
y ( ) y
• Triggered by changes to material masters or changes sent on 
a regular basis (every shift, once a day, …)
– Widely used in MOM activities to identify materials
y y
• Material Inventory
– Represented in “Material Lot” & “Material Sublot”
– Contains quantity, location, status information and 
company specific properties
• Example: pH, octane, “Use by date”, QA status, …

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Material Information – ISA 95 Model
• Exchange information about properties of 
material lots sublots definitions and classes
material lots, sublots, definitions, and classes Is assembled from

Is assembled from Is assembled from Is assembled from

0 n
0..n 0 n
0..n 0 n
0..n 0 n
0..n 0 n
0..n 0 n
0..n
Defines
Made up of
Material a grouping Material 0..n Material
Material Lot
Class 0..n 0..n Definition 1..1 Defined by 0..n Sublot

0..n
Has Has Is tested Has
properties
p p properties
p p Is tested values for Has
by a > b a>
by values for
f
of Is tested of May be made up
by a > 0..n 0..n of sublots
0..n
Material Test
0..n Specification
Is tested Records the
0..n 0..n execution of
by a >
Is tested Defines a Q
QA Test
by a > procedure Result
for
0..n 0..n 0..n obtaining a 0..n
Material Material 0..n 0..n 0..n
Material Lot
Class Definition
May Maps to Property
Property map to Property

0..n 0..n 0..n

< may contain nested < may contain nested < may contain nested

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Material Information – B2MML 
Document
<Material>
<MaterialLot>
<ID> W89 </ID>
<Description> A lot of material </Description>
<MaterialDefinitionID “WXE908”
WXE908” />
<Location> Tank 1 </Location>
<Quantity UnitOfMeasure = "KLKL" > 4500
</Quantity>
<MaterialLotProperty>
<ID> dateTimeProduction </ID>
<Value> 2001
2001-
-01
01-
-06T00:14:23+11:30 </Value>
</MaterialLotProperty>
<MaterialLotProperty>
<ID> Quality Status </ID>
/
<Value> Good </Value>
</MaterialLotProperty>
</MaterialLot>
</Material>

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Role Based Equipment Information
• Exchange information about properties of specific equipment and equipment 
classes
• The specific properties are defined by the end user
– Example: Validated for specific equipment, in‐use, sterile, benchmark capacity, heat transfer 
efficiency, …
< May be made up of
0
0..n

Equipment 0..n
Equipment
Class 0..n < Defined by
0..n 0..n
Has Has
properties
p p Is tested Is tested values for >
of > b an >
by b an >
by
0..n 0..n

Equipment
Capability Test
Specification
0..n 0..n < Records the Equipment
Defines a execution of Capability Test
0..n Is tested procedure for Result
by an > obtaining an > 0..n

Equipment 0..n 0..n Equipment

Class Property Maps to Property

0..n 0..n
< may contain nested < may contain nested

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Physical Asset Information
• Exchange information about properties of specific physical 
assets and physical asset classes
assets and physical asset classes
• The specific properties are defined by the end user
– Example: In maintenance, last used date, stock power, …
> May be made up of
0..n

> is an instance of
Physical 1..1 Physical
Asset 0..n Asset Class
0..n 0..n

Has IIs tested

d IIs tested
d Has
values for > by an > by an > properties
0..n 0..n of >

Physical Asset
Capability Test
< records the Specification
Physical Asset
y
t ti off
testing 0..n 0..n
Capability Test
Result Defines a
procedure for Is tested
0..n obtaining an < by an < 0..n

Physical 0..n Maps to 0..n Physical

Asset Asset Class
Property Property

0..n 0..n
< may contain nested < may contain nested

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Operations Schedule
• What actions to perform
– Materials to make
– Priority and/or dates
– Wh t t i l t
What materials to use
– What equipment to use
– What personnel to use
What personnel to use
– Production parameters (e.g. Color, Options,…)
• Per
Per Segment (step in production)
Segment (step in production)
• Per location (Site, Area, …)
• Per week, day, shift, order, …
Per week day shift order

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Scheduling Hierarchy

Business Plan (API CS)

(Per Business Area, Per Time)

M k ti
Marketing Plan
Pl (API CS)
(Per Product Family, Per Time)
I SA-95.00.01 - 1.1 Production Forecasting Activity

Production Plan ((API CS))

(Per Product, Per Time)
I SA-95.00.01 - 2.4 Production Scheduling Activity

Operations Schedule (I SA 95) - Master Production Schedule (API CS)

(Per Site, Per Product, Per Time)

I SA-95.00.03 Detailed Production Scheduling Activity

Work Schedule (I SA 95)

(Per Line, Per Product, Per Time)

I SA 95
95.00.03
00 03 - Production Dispatching Activity

Job List (I SA 95) & Batch List (I SA 88)

(Per Process Cell, Per Batch)

I SA 88.00.01 - Process Management Activity - I SA 95.00.03 Production Execution Activity

Work Directive (I SA 95) & Control Recipe (I SA 88)

(Per Unit, Per Batch)

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Operations Schedule
Operations
Schedule

Is made up of
1..n
May correspond
Operations to an < Operations
Definition Request

Is made up of

May correspond 1..n 0..n

to an <
Requested
Process  Segment Segment
Segment Corresponds Requirement Response
to an <
0..n
May contain
May contain

0..n 0..n 0..n 0..n 0..n

Segment Personnel Equipment Physical Asset

Physical Asset Material
Parameter Requirement Requirement Requirement Requirement 0..n
Is assem bled
0..n
from
May be made up of
1..n 1..n 1..n 1..n
Personnel Equipment Physical Asset
Physical Asset Material
Material 
Requirement Requirement Requirement Requirement
Property Property Property Property

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 Operations Performance
• What was done
– What material was produced & how much
– What material was consumed or used & how 
much
h
– What equipment was used & how long
– What personnel were used & how long
Wh t l d&h l
• Per Segment (step in production)
• Per location (Site, Area, …)
l ( )
• Per week, day, shift, order, …

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 It Takes More Than Just Schemas
• The B2MML standard defines the structure of 
integration data
• But, it does not define the detailed definition 
of the source and target exchanged data 
• B2MML provides a template or format, much 
as a blank check, but does not specify the 
source or destination of the data in the 
application name space
li ti
• Multiple methods exist for data mapping

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 An XML Example
Production Schedule
Production Schedule
Operation
p Schedule
Operation Request

Segment Requirement

Material Produced

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 Production Performance 
Mapped to SAP PI PCS Interface
Mapped to SAP PI‐PCS Interface

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ProductionPerformance_Vimmerby_2002.vsd The power of knowing what MESAKNOWS
 Material Produced,
Material Consumed to SAP
Material Consumed to SAP

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 Data Mapping
B2MML Mapping Spreadsheets
B2MML Mapping Spreadsheets
• Document mapping in format suitable for implementation
• Available on the WBF web site

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 ISA 95 Part 5 ‐ Transactions
Verb Description
GET Request to a receiver for information on one or more objects. The response is a SHOW
message.
The receiver returns a SHOW message containing all the specified attributes and all the
specified contained elements of the specified nouns. If no attribute or contained element is
specified in the noun area, then all attributes and/or contained elements shall be returned.
When wildcards are applied to the noun and property IDs, it shall be possible to further filter
th iinformation
the f ti tto b
be returned
t db
by specifying
if i a value
l ffor one or more attributes
tt ib t off the
th noun.
Only objects whose attributes match the specified value (out of the list of objects matching
the wildcards applied to noun and property IDs) shall be returned.

PROCESS Request to a receiver to process new information. The response is an ACKNOWLEDGE

message.
A new noun is added.

CANCEL Request to a receiver to remove information.

The specified noun is canceled.

CHANGE Request to a receiver to change information. The response is a RESPOND message.

The specified attributes and contained elements of the noun are changed.

SYNC ADD Request from the owner of the object to add information.

SYNC CHANGE Request from the owner of the object to change information.

SYNC DELETE Req est from the o

Request owner
ner of the object to delete information
information.

CONFIRM Confirmation response to a request.

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 Push Transactions in Business Process

ERP PROCESS – Production Schedule MOM

Level 4 Level 3
Production  PROCESS – Production Performance Some work
Scheduling complete
PROCESS* – Production Performance
All
All work finished
k fi i h d

Scenario assumptions: 
1. ERP send production schedule to MOM for processing
2. MOM (Manufacturing Operations Management) sends production performance to ERP for 
processing 

* Message contains a FINAL flag to indicate that the message is the final production performance 
for the associated production schedule
for the associated production schedule. 

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 Push and Pull
Manage Material Lot Quantity
Manage Material Lot Quantity
ERP MOM
L l4
Level 4 L l3
Level 3
New material lot
is available GET – Material Lot (ReceiptStatus = “New”)
SHOW
S O – Material
ate a Lot
ot (qua
(quantity
t ty = 400)
00)

CHANGE – Material Lot (quantity = 300) Material lot

quantity changed

CHANGE – Material Lot (quantity = 200) Material lot

quantity changed
quantity changed

CHANGE – Material Lot (quantity = 0) Material lot

quantity changed

Scenario assumptions: 
1. MOM requests material lot information from ERP
2. ERP sends information on new material lots (lots with no changes)
3. MOM pushes quantity changes in material lot to ERP 

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 Applications Need To “Talk”
Application “ERP” Application “MES”

• Integration is application‐to‐application data exchange
, g , ,
• Across firewalls, through APIs, web services or flat files, 
across a wire, often in different languages, data 
formats, at different time cycles, on different systems, 
of different ages supported by different departments
of different ages, supported by different departments, 
…
yp p
• ISA 95 and B2MML only provide part of the solution

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 Integration ‐ The Current Situation
• Message based protocols have become the standard model for enterprise 
integration 
• Enterprise Service Buses (ESB) have become the standard model for 
exchanging integration messages 
• XML has become the standard model for data representation within 
messages 
• SOAP and REST have become the standard interfaces to ESBs 
• Web services have become the standard for SOAP implementations 
p

Application Message Application

SOAP XML XML REST
A B

Enterprise
Service Bus
Application Web Application
SOAP XML XML S i
Service
C D

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 Integration : The Hidden Complexity 
• Every integration project needs the following elements
• Some communication is one way n
S i ti i nÆo

1
Application Thor Convert Local Convert Local Send ESB
“Thor” Data format to names to information to
Store Global format Global names ESB Server

Application Apollo
Convert Global Convert Global Receive
2 ESB
“Apollo” Data format to Local names to information
Store format Local names from ESB Server

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 Integration – Two Way Communication
• Multiple translations, copies, services, …
Some communication is two way n Æ o Æ p Æ q
• Some communication is two‐way n
1
Convert Local Convert Local Send
format to names to information to
Global format Global names ESB
Application Thor ESB
“Thor” Data
Store Convert Global Convert Global Receive Server
format to Local names to information
format Local names from ESB
4
Convert Global Convert Global Receive
2
format to Local names to information
format Local names from ESB
Handle Application Apollo ESB
Transaction “Apollo” Data
Logic Store Convert Local Convert Local Send
Server
format to names to information to
Global format Global names ESB

3
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 Many Layers for Integration
• Convert Formats (B2MML) • Link to ESB
– From
From local to project selected 
local to project selected – API, Web Service, …
API Web Service
common (canonical) formats • Exchange Messages across 
– From canonical to local  ESB
format
– IP
IP, Internet, Ethernet, WAN, 
Internet Ethernet WAN
• Convert Names VPN, ,,,
(Planned ISA 95 TR.02) • Transaction Logic 
– From local names to common  – Rules for handling of 
g
names (tags status )
names (tags, status, …) messages
– From common names to local 
names
• Send/Receive
Send/Receive messages
messages 5
(Planned ISA 95 TR.03) 1 2 3 4
– Publish‐Subscribe methods 6
– Query‐Response methods
y p

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 B2MML Implementations
• Multiple publicly discussed implementations:
– Nestle, Arla Food, Cerveceria Polar, P&G
– All have SAP as at least one of the ERP systems connected
• Technically
– The solutions are not much different from each other
– All using Business Connector combined with different 
access to R/3: PI‐PCS, IDOCS, BAPI calls, XI.
• All experienced significant improvements in integration 
efforts
– For connection to different ERP systems
– For connection to different MES and control systems

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 ISA95 Part 3
ISA95 Part 3

Models of Manufacturing 
Operations

The new model for MES

M ESA KNOWS
SUSTAINABILITY & ECO‐EFFICIENCY ‐ LEAN ‐ METRICS & PERFORMANCE MANAGEMENT
INFORMATION INTEGRATION ‐ SAFETY ‐ ASSET PERFORMANCE MANAGEMENT ‐ B2MML
QUALITY & COMPLIANCE ‐ PRODUCT LIFECYCLE MANAGEMENT ‐ AUTOMATION

Do you know M ESA?
 ISA 95
4 Categories of MOM Activities
4 Categories of MOM Activities
• Production Operations Management
– Activities that coordinate, direct, manage & track the functions that use raw 
ct t es t at coo d ate, d ect, a age & t ac t e u ct o s t at use a
materials, energy, equipment, personnel and information to produce products 
• Quality Operations Management
– Activities which coordinate, direct & track the functions that measure and 
report on quality
report on quality
• Inventory Operations Management
– Activities which coordinate, direct & track the functions that manage and track 
the inventory of product and/or material and their movements
• M i O i M
Maintenance Operations Management
– Activities which coordinate, direct and track the functions that maintain the 
equipment, tools and related assets to ensure their availability for 
manufacturing 

• Models have also been applied to: 
– Shipping, Receiving, Transportation, …

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 Models of Production Activities & Data
Operation Resource Operations Operations Operations
definition information capability schedule performance

Detailed
production KPI s
scheduling ( I SO 22400)
Physical
Assets
Production
Production
resource
tracking
management

Production
Production
Performance
dispatching
analysis
y

Product Production
definition data
management collection

Production
P d i
execution
management
Equipment and process Operational Operational Equipment and process
specific production rules commands responses specific data

Level 1-2 Functions

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 Maintenance Operations
Maintenance Maintenance Maintenance Maintenance
definitions capability request response

Detailed
maintenance
scheduling

Maintenance
Maintenance
resource
tracking
management

Maintenance Maintenance
dispatching analysis

Maintenance Maintenance
definition data
management collection

Maintenance
execution
management
Maintenance Equipment
Equipment specific Maintenance
commands and state of
maintenance procedures results
procedures health data

Level 0-1-2 personnel & equipment

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 Quality Test Operations
Quality test Quality test Quality test Quality test
definitions capability request response

Detailed
quality test
scheduling

Quality
Quality test
test resource
tracking
management

Quality
Quality test
performance
dispatching
analysis
Quality Quality
test definition test data
management collection
Quality
Q li test
execution
managent
Quality
Test Test Quality
parameters and
commands responses specific data
procedures

Level 0-1-2 equipment

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 Material Movement and Inventory 
Transfer Activities
Transfer Activities
I nventory I nventory I nventory I nventory
definitions capability request response

Detailed
inventory
scheduling
I nventory
I nventory
resource
tracking
management

I nventory I nventory
dispatching analysis

I nventory I nventory
definition data
management collection
I nventory
execution
management

I nventory I nventory I nventory I nventory

storage definitions commands replies specific data

Level 0-1-2
inventory equipment

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 All Operations Categories
Operations Resource Operations Operations Operations
definition information capability schedule performance

KPI s
( I SO 22400)
Physical
Assets

E i
Equipment t and
d process O ti l
Operational O ti l
Operational E i
Equipment t and
d process
specific production rules commands responses specific data

Level 1-2 Functions

Copyright 2012, MESA International The power of knowing what MESAKNOWS
 ISA 95
Requirements for MOM
Requirements for MOM
• The ISA 95 Part 3 standard defines about > 80% of the activities that 
occur in Manufacturing Operations Management (MOM)
occur in Manufacturing Operations Management (MOM)
– Production Operations Management
– Maintenance Operations Management
– Laboratory (Quality) Operations Management
– Material Handling & Storage (Inventory) Operations Management
– Supporting activities
• Management of security
• M
Management of information
t fi f ti
• Management of configuration
• Management of documents
• Management of regulatory compliance
• Management of incidents and deviations

• Activities are used as a map to identify MOM requirements

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 ISA 95.03 Format
• Part 3 defines the tasks 
and activities for all 4
and activities for all 4 
categories of MOM
– It is a straight forward 
process to convert these
process to convert these 
into requirements
• Most MOM/MES users 
are using this outline to
are using this outline to 
generate their MOM 
requirements
– Not
Not all projects cover all 
all projects cover all
categories
– Not all projects cover all 
activities within a category

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 Activities and
Tasks
• Standard lists tasks that 
occur in each activityy
• The standard does not 
specify an architecture or 
organization
• Task list can be quickly
Task list can be quickly 
converted into 
requirements
• Identify which activities are 
t b
to be supported
t d
• Identify which resources 
(equipment, personnel, 
material) are to be 
supported
• Write requirements using 
ISA 95 terminology

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 ISA 95 Part 3 ‐ Template for User 
Requirement Specifications
Requirement Specifications
• Typical end user 
q (
requirements (URS))

• Being used to compare 
different vendor’s 
functionality and
functionality and 
capabilities

• We finally have a vendor 
independent description 
of MOM/MES

• We finally have a common 
We finally have a common
way to  compare different 
facilities

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 MOM Boundary Defines the 
Requirement’s scope
Requirement s scope
Product Production Production Production
definition capability schedule performance

Detailed
production
scheduling

Production
Production
oduct o
resource
tracking
management

Production ( QA) Product

dispatching analysis

Product Production
definition data
management collection

Production
P d ti Production
P d ti
execution analysis

Level 2 Process Control

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 For All Categories
• Determine which areas are covered by the 
i l
implementation
t ti
• Most implementations cover 1 or 2 categories
• Determine the line of responsibility for each category
Determine the line of responsibility for each category
Maintenance Production Quality I nventory
Maintenance Maintenance Maintenance Maintenance Product Production Production Production
Definitions definition capability schedule performance I nventory I nventory I nventory I nventory
Capability Schedule Performance Quality Quality test Quality test Quality test
transfer transfer transfer transfer
definitions capability schedule performance
definitions capability request response

Maintenance
Requests Detailed Detailed
Maintenance Quality test
production Detailed
Maintenance Responses requests Detailed
scheduling Quality test transfer
Scheduling quality test responses scheduling
scheduling
Maintenance Production
Maintenance Production Transfer
Resource resource Quality Transfer
Tracking tracking Quality test resource
Management management test resource tracking
tracking management
management

Maintenance Production Transfer Transfer

Maintenance Analysis
dispatching Quality test Quality
Dispatching Analysis dispatching analysis
dispatching analysis

Maintenance Maintenance Product Production Quality Quality Transfer Transfer

Definition Data definition data definition test data definition data
Management Collection management collection management collection management collection

Quality test Transfer

Maintenance Production
execution execution
Execution execution

Level 2

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 Example: Equipment / Vessel Tracking
• At a process company one main issue was tracking 
t
transfer vessels, their status (clean, sterile, in use, …) 
f l th i t t ( l t il i )
and location (in plant and between plants)
• Limited MES installed to track equipment resources
Limited MES installed to track equipment resources

• Reduced delays y
due to vessel
availability and
eliminated errors
eliminated errors
due to incorrect
equipment

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 Example: Investigations & RFT Studies
• Major company’s goal was reduce incident 
i
investigation time & RFT study time, >80% spent 
ti ti ti & RFT t d ti 80% t
collecting data
• Installed a limited MES for Data Collection & Analysis
Installed a limited MES for Data Collection & Analysis

• Initial implementations
have significantly
reduced study
and investigation times
and investigation times

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 Typical Initial MES Implementation
Product Resource Production Production Production
definition information capability schedule performance

Detailed
production
scheduling

Production
Production
resource
management MES tracking

Production
Production
Performance
dispatching
analysis

Product Production
definition data
management collection

Production Historian
execution
management

Level 1-2 Functions

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 The Typical MES / DCS Pattern
Product Resource Production Production Production
definition information capability schedule performance

Detailed
production
scheduling

Production
Production
resource
management MES tracking

Production
Production
Performance
dispatching
analysis

Product Production
definition data
management collection

Production
execution
management
DCS
Level 1-2 Functions

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 Commercial MOM/MES Systems
• Mostly based on ISA 95 and ISA 88 standards
• Most solutions still focused on industry segments
M t l ti till f d i d t t
– Pharmaceutical
– Automotive 
– Discrete Assembly
– Food and Beverage 
– Process Industries
Process Industries
• Site implementations range from 200K – 2M USD 
depending on scope and customization required
• Paybacks come from 2%‐3% year to year productivity 
improvements
– Because of ability to “lock‐in” best practice procedures 
y p p

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 Summary
• ISA 95 provides a vendor independent description of 
MOM/MES
• Provides a vendor independent and user independent 
format for MOM requirements
format for MOM requirements
• Vertical integration of system is usually required to 
achieve full MOM benefits
• Well documented benefits from MOM 
implementations are driving additional 
implementations
• Most vendors are supporting the ISA 95 standard and 
are using it to describe their products’ functionality

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 ISA 95 / MOM / B2MML Questions

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Copyright 2012, MESA International The power of knowing what MESAKNOWS