Yokogawa Electric Corporation Yokogawa ISA-95 Copyright © Yokogawa Electric Corporation April 8, 2005 Friday, November 20, 2015 System Integration using.
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Yokogawa Electric Corporation
Yokogawa ISA-95Copyright © Yokogawa Electric CorporationApril 8, 2005
Thursday, April 20, 2023
System Integration usingISA-95
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Outline
What is ISA-95?– Parts 1 & 2 Enterprise-Control System Integration– Part 3 Manufacturing Operations
Yokogawa support for ISA-95– Standard development– Enterprise integration– Manufacturing Operations
Implementing ISA-95– Analysis & Design– Implementation
Yokogawa Electric Corporation
Yokogawa ISA-95Copyright © Yokogawa Electric CorporationApril 8, 2005
What is ISA-95?
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 is Multi-part Standard
Part 1:– ANSI/ISA 95.00.01 “Enterprise - Control System Integration -
Part 1: Models and Terminology”– IEC/ISO 62264-1
• Joint international standard
Part 2:– ANSI-ISA 95.00.02 “Enterprise - Control System Integration -
Part 2: Object Attributes”– IEC/ISO 62264-2
• In final stages of approval
Part 3:– Work in Progress– Models of Manufacturing Operations
SP95 is the committee developing the ISA-95 standards
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Why is ISA-95 Needed?
Integration of business and manufacturing systems is difficult– Different systems, cultures, terminology...– Integration projects are expensive– Lack of consensus and models to follow for integration
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 Provides
Framework for integrating business and control systems
– Separation of the business processes from the manufacturing processes
– Focus on functions, not systems, organizations or individuals
• Can be applied regardless of the degree of automation
– Clear description of exchanged information
Vendor independence
Emphasize on best practices for integration of enterprise and control systems
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 Benefits
Reduce cost of integrating business systems with manufacturing systems
Vendor independent design tool focuses work on interfaces, not specific products
Results in more robust, loosely coupled systems for lower maintenance costs and lower TCO
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 Functional Hierarchy
Business Planning & Logistics
Plant Production Scheduling,Operational Management, etc
ManufacturingOperations & Control
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
ContinuousControl
Level 4
Level 3
Levels2,1,0
Parts 1 & 2 addressthis interface
DiscreteControl
BatchControl
ISA-95.00.01 Figure 3
ISA-88Standard
ISA-95Part 3
Standard
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 Equipment Hierarchy
May contain 1 or more
May contain 1 or more
May contain 1 or more
Lowest LevelsOf Equipment
Typically Scheduled
By Levels 3 or 4
Level 3 activitiestypically deal withthese objects
May contain 1 or more
Must contain 1 or more May contain 1 or more
ProductionUnit
Process Cell
Level 4 activitiestypically deal withthese objects
Lower level equipment usedin repetitive or
discrete operations
Lower levelequipment used
in batch operations
Lower levelequipment used
in continuousoperations
May contain 1 or more
Area
Site
Enterprise
ProductionLine
Unit Work Cell
ISA-95.00.01 Figure 4
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Categories of Information
Manufacturing operations &control information
Production operations, maintenanceoperations, quality operations, etc.
Business planning &logistics information
Plant production scheduling,operational management, etc.
Productdefinition
information(What must be
defined to makea product)
Productioncapability
information(What resources
are available)
Productionschedule
information(What to
make and use)
Productionresponse
information(What was
made and used)
ISA-95.00.03 Draft 13 Figure 3
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Interface Categories
Pro
duct
ion
Res
pons
e
Production
Schedule
Business Planning &Logistics Information
ProductionDefinition
Manufacturing Operations &Control Information
ProductionCapability
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Capability
Business Planning &Logistics Information
Manufacturing Operations &Control Information
ProductionCapability
• Production Capability
• Input to planning
• What resources are available to be scheduled?
• Personnel
• Equipment
• Material
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Product Definition
Business Planning &Logistics Information
ProductionDefinition
Manufacturing Operations &Control Information
• Consists of Product Segments
• Each Product Segment specified by
• Product Parameter
• Personnel Specification
• Equipment Specification
• Material Specification
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Schedule & Response
Pro
duct
ion
Res
pons
e
Production
Schedule
Business Planning &Logistics Information
Manufacturing Operations &Control Information
• Matching schedules & responses
• May be broken down into Segments
• Product Parameter
• Personnel
• Equipment
• Material Produced/Consumed
• Consumable
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Data Flows for Batch Processes
Pro
duct
ion
Res
pons
e
Production
Schedule
Business Planning &Logistics Information
ProductionDefinition
Manufacturing Operations &Control Information
ProductionCapability
Equipment/Asset Availability
Recipes What to make, when to make it
Batch Record
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Enterprise - Control Domain Boundary
FunctionsOutside the
Control Domain(e.g. Production Scheduling)
(e.g. Production Schedule and Production Results)
Information Flows of interest
FunctionsWithin the
Control Domain(e.g. Equipment Monitoring)
Enterprise/Control System Boundary
Functions detailed
Functions not detailed
Data flows detailed
Data flows not detailed
ISA-95.00.01 Figure 2
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 Part 1 & 2 Object Models
Part 1 defines object models to define resources and categories of information to be exchanged– Object models designed using Unified Modeling
Language (UML)– Enable software designs in different languages and
formats to be created
Part 2 defines attributes (or properties) for each object defined in Part 1– Attributes add meaning and detail to the objects
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Capability and Product Definition are used as inputs to the Enterprise Planning/Scheduling function
Production Schedules exist in different levels of detail. Enterprise plans and schedules are usually course schedules used to create lower level, more detailed schedules.
Production Performance reports actual performance to the Enterprise
Object Models
Resource Object Models
– Personnel
– Equipment
– Material (and Energy)
– Process Segments
Categories of Information Object Models
– Production Capability
– Product Definition
– Production Schedule
– Production Performance
Personnel, Equipment & Material Resources are the basis for all ISA-95 information
These resources may be grouped into segments to partition an area or product definition
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Sample Object Model and Attributes
AttributeName
Description Examples
ID A unique identification of a specific piece ofequipment, within the scope of the informationexchanged (Production Capability, ProductionSchedule, Production Performance, …)
The ID is used in other parts of the model whenthe equipment must be identified, such as theproduction capability for this person, or aproduction response identifying the equipment.
R7726
Reactor 101
Lathe machine 33
Description Additional information about the equipment.
ISA-95.00.02EquipmentAttributes
ISA-95.00.01 Equipment
model
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Schedule
PersonnelRequirement
EquipmentRequirement
MaterialProduced
Requirement
PersonnelModel
EquipmentModel
MaterialModel
Corresponds to element in(see Figure 1)
Corresponds to element in(see Figure 1)
Corresponds to element in(see Figure 1)
May contain
0..n 0..n0..n0..n
1..n
PersonnelRequirement
Property
EquipmentRequirement
Property
Material ProducedRequirement
Property
1..n 1..n 1..n
ProductionSchedule
ProductParameter
ProcessParameter
Material ConsumedRequirement
Corresponds to element in(see Figure 1)
0..n
Material ConsumedRequirement
Property
1..n
ConsumableExpected
0..n
ConsumableExpectedProperty
1..n
SegmentRequirement
1..n
Is made up of
Is made up of
Is associatedto either
Product Segmentor
Process Segment
RequestedSegmentResponse
Correspondsto a
May Correspondto a
ProductionParameter
ProductionRequest
0..n
0..n
1..1
0..n
1..1
0..n
1..1
0..n
1..1
ProductProduction
Rule
Production ScheduleIDStart & End TimeProduction Request
IDStart & End TimeSegment Requirement
IDStart & End TimeParameterPersonnel RequirementEquipment RequirementMaterial Produced
RequirementMaterial Consumed
RequirementConsumable Expected
RequirementSegment Requirement
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 Part 3
Models of Manufacturing OperationsRecognizes that Enterprise-Control domain boundary will varyFocuses on MES functions in Level 3Many of these functions may be placed in the enterprise or control system domain– Dependant upon the business, company, application
Part 3 defines the functions in Level 3 – Parts 4 and probably 5 will define the data models and
attributes.
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Manufacturing Operations
Manufacturing Operations consists of:– Production Operations– Maintenance Operations– Quality Operations– Inventory Operations
Each operations type has unique data that must be exchanged between levels 3 and 4
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Activities InsideThe Enterprise Domain(e.g. Production Scheduling) (e.g. Production Schedule)
Part 1 & 2 Information Flows of interest
ActivitiesWithin ManufacturingOperations(e.g. Production Dispatching)
Enterprise/Control System Boundary
Activity detailed
Activity not detailed
Data flows detailed
Data flows not detailed
Level 4
Level 3
Level 2
Part 3 Information Flows
Manufacturing Operations Process Control SystemBoundary
Level 3 MES Functions
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ResourceManagement
Analysis
DataCollection
Execution
Dispatching
Tracking
DetailedScheduling
Level 2 Process Control
Definitionmanagement
OperationsCapability
OperationsPerformance
OperationsSchedule
OperationsDefinition
ED
B
A
C
Level 3 & 4 Boundaries Vary
Level 4
Level 3
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ProductionResource
Management
ProductionCapability
ProductionAnalysis
(QA) ProductAnalysis
ProductionData
Collection
ProductionExecution
ProductionDispatching
ProductionTracking
ProductionPerformance
DetailedProductionScheduling
ProductionSchedule
Level 2 Process Control
ProductDefinition
Management
ProductDefinition
Part 3 Manufacturing Operations Functions
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Inventorydata
collection
Inventoryexecution
Inventory resource
management
Inventorydispatching
Inventorytracking
Inventory
response
Detailedinventoryscheduling
Inventoryrequest
Inventorydefinition
management
Inventoryanalysis
Inventorycapability
Inventorydefinitions
Productiondata
collection
Productionexecution
Productionresource
management
Productiondispatching
Productiontracking
Productionperformance
Detailedproductionscheduling
Productionschedule
Productdefinition
management
Analysis
Productioncapability
Productdefinition
MaintenanceData
Collection
MaintenanceExecution
MaintenanceResource
Management
MaintenanceDispatching
MaintenanceTracking
MaintenancePerformance
DetailedMaintenanceScheduling
MaintenanceSchedule
MaintenanceDefinition
Management
MaintenanceRequests
MaintenanceCapability
MaintenanceResponses
MaintenanceAnalysis
MaintenanceDefinitions
Qualityanalysis
Qualitytest datacollection
Quality testexecution
Qualitytest resourcemanagement
Quality testdispatching
Quality testtracking
Quality testperformance
Detailedquality testscheduling
Quality testschedule
Qualitydefinition
management
Quality testrequests
Quality testcapability
Quality testresponses
Qualitydefinitions
Maintenance Production Quality Inventory
X
MES Functional Categories
Level 2
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
ISA-95 vs. MESA
MESA– Originally “Manufacturing Execution Systems
Association”– Now “Manufacturing Enterprise Solutions Association”
MESA model provided focus for MES– Collection of functions– Systems biased– No detail
ISA-95 Part 3– Functional based– End-user driven
• Purdue Model
– Detailed• Data flows• Objects & Attributes
Operations/Detailed
Scheduling
ResourceAllocation& Status
PerformanceAnalysis
DocumentControl
ProductTracking &Genealogy
DispatchingProduction
Units
MaintenanceManagement
LabourManagement
ProcessManagement
QualityManagement
DataCollectionAcquisition
MES
SupplyChain
Management
EnterpriseResourcePlanning
Product/Process
Engineering
Controls
Sales &Service
Management
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Who is Using ISA-95
End users– Using the standard for new integration projects
• Arla Foods• Proctor & Gamble• Nestle• Eli Lilly
ISA-95 provides models for use in analysis B2MML (Business To Manufacturing Markup Language) provides tools for implementation– XML schemas developed by SP95 members working
under the World Batch Forum (WBF)– IT tool for use on integration projects– Standard, vendor neutral, for integration projects
Yokogawa Electric Corporation
Yokogawa ISA-95Copyright © Yokogawa Electric CorporationApril 8, 2005
Yokogawa Support for ISA-95
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Support for Standards Development
Yokogawa has been active in the creation of all parts of the ISA-95 standardYokogawa developed the B2MML XML Schemas for the World Batch ForumYokogawa contributing our ISA-95 and OPC expertise to create a new Open O&M standard– Open O&M = Open Operations & Maintenance– Integrate ISA-95 operations and maintenance functions
with MIMOSA’s (www.mimosa.org) open system architecture for asset management
– Use OPC as the transport for the Open O&M content
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
e-RM Architecture based on three chains
MES
Procure-ment
Procure-ment
Mainte
-nanceMainte
-nance
ERP
PCS
FieldSolutions
Produc-tion
Produc-tion
Distri- bution Distri- bution SalesSales
Construc
-tionConstruc
-tion
DesignDesign
Operation
Operation
Engineering Chain(Product Lifecycle
Management)
Engineering Chain(Product Lifecycle
Management)
Enterprise-Production Chain
Enterprise-Production Chain
Supply ChainSupply Chain
ISA-95ISA-95
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Integrated Suite of Solutions
Yokogawa offers an integrated suite of proven software tools, designed to support the operational optimization of batch and
continuous process’s
Process Control and Instrumentation
Process Data Historian
Reconciled Operational Information
Operational Excellence Applications
Enterprise Resource Planning
Exaquantum/PIMS/Batch/SERPRM
ExaOMS
Enterprise Resource Planning
ExaSMOC
ExaSPOT
ExaRQE
ExaplogExapilotVisaOA
MVisaEMVisaPMVisaMB
VisaDRVisaPA
ExaopcCS 3000, CS Batch 3000, Stardom
Fieldbus and Instruments
ISA 95 Parts 1 &
2
ISA 95 Part 3
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Part 1 & 2 Solutions
Enterprise-Control System Integration– ISA-95 used for integration architecture– B2MML (Business To Manufacturing Markup Language)
used for implementation• Customized as required for each project
Focuses on Production Schedule & Response– Largest demand is for ERP-PAS integration– Leading ERP system for
industries is SAP
SAP R/3 integration – PP-PI – Production Planning
for Process Industries– PM – Plant Maintenance– MM – Materials Management
Business Planning &Logistics Information
Production
Definition
Manufacturing Operations &Control Information
Production
Capability
ProductionSchedule
ProductionResponse
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Enterprise-Control Integration
Intelligent Instruments
CS Batch 3000
OPC
Exaquantum/Batch
OP
CO
PC
IntelligentEquipment DCSs, PLCs
LIMS
Enterprise Systems(SAP, Oracle,…)
Manufacturing Operations & Control Information
Business Planning &Logistics Information
Production
Definition
ProductionSchedule
ProductionResponse
Production
Capability
Plant Resource Manager
B2MML Adapter (ISA-95)
B2MML Adapter (ISA-95)
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Response
Exaquantum/Batch
Enterprise Systems(SAP, Oracle,…)
Manufacturing Operations & Control Information
Business Planning &Logistics Information
ProductionSchedule
ProductionResponse
Production Response– Specified response part
of Production Schedule, or– Configured as part of B2MML
interface
Exaquantum/Batch organizes data by Production Run (Batch)– All results data stored in integrated
database– Includes data from beyond the DCS
• LIMS• Packaging• Manual Activities
Exaquantum/Batch B2MML adapter builds Production Response and transmits to Enterprise level B2MML adapter
B2MML Adapter (ISA-95)
B2MML Adapter (ISA-95)
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Capability
Exaquantum/Batch
Enterprise Systems(SAP, Oracle,…)
Manufacturing Operations & Control Information
Business Planning &Logistics InformationCapability information used as
input to planning & schedulingCapability =– Equipment– Personnel– MaterialAvailable for production
operations
Manufacturing operations contributes asset availability data to enterprise systems
B2MML Adapter (ISA-95)
B2MML Adapter (ISA-95)
Production
Capability
Capaci
ty
Pro
du
ctio
n
Cap
aci
ty
Unattainable Capacity
Available Capacity
Committed Capacity
Time
Current Production Capacity
Requires tight Operations & Maintenance integration
Material & Personnel data usually available in the Enterprise
domain, not the Control domain
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Product Definition
Exaquantum/Batch
Enterprise Systems(SAP, Oracle,…)
Manufacturing Operations & Control Information
Business Planning &Logistics InformationProduct Definition is very
process/industry specific– Continuous
• Small factor, sometimes collections of formula/setpoints
• Good fit for B2MML
– Batch• Recipe driven• ISA-88.00.03 defines General &
Site Recipes• Implement outside of B2MML
depending upon General/Site Recipe system
– Discrete• BOM driven• Implementation method
depends upon Enterprise & Control Systems
B2MML Adapter (ISA-95)
B2MML Adapter (ISA-95)
Production
Definition
Enterprise requirements drive data flow direction & content
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Benefit of B2MML
Decouples Enterprise & Control systems– Fewer dependencies increases
robustness
Vendor neutralStandards basedEnables common data format when multiple manufacturing sites are integratedCommon industry approach– Arla Foods– Nestle– Proctor & Gamble
Defacto standard among end-users for ISA-95 implementations
Exaquantum/Batch
Enterprise Systems(SAP, Oracle,…)
Manufacturing Operations & Control
Information
Business Planning &Logistics
Information
ProductionSchedule
ProductionResponse
B2MML Adapter (ISA-95)
B2MML Adapter (ISA-95)
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Part 3 Solutions
Manufacturing Operations– Production Operations
• Intelligent Field Instruments• Plant Resource Management• Distributed Control Systems• Network Control Systems• Plant Information Systems• Advanced Operation Assistance
– Maintenance Operations• Maximo
– Quality Operations• LIMS Integration
– Inventory Operations• Warehouse Management System Integration
Part 3 is still under development.
When the standard is released Yokogawa will
support the development of B2MML extensions
B2MML XML schemas will be the preferred data
exchange format for ISA-95 Part 3 Data
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Productionresource
management
Productioncapability
Productionanalysis
(QA) Productanalysis
Productiondata
collection
Productionexecution
Productiondispatching
Productiontracking
ProductionPerformance
Detailedproductionscheduling
Productionschedule
Level 2 Process Control
Productdefinition
management
ProductDefinition
Production Operations Support
Exaquantum/Batch
3rd Party Scheduling Packages
CS Batch 3000
CS Batch 3000Smart Field
InstrumentsNetworkSolution
s
AdvancedOperation Assistance
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Production Operations
Centered on Process Automation Systems– Production management
• Controlling production, not just the process
– Process optimization• Advanced Operations Assistance
– Production analysis• Exaquantum/Batch provides product and production
analysis data
OPC is the preferred transport for production operations dataWhen ISA-95 Production Operations standard is completed B2MML will be expanded to support maintenance data
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Maintenanceresource
management
MaintenanceCapability
Maintenanceanalysis
Maintenancedata
collection
Maintenanceexecution
Maintenancedispatching
Maintenancetracking
MaintenanceResponse
DetailedMaintenancescheduling
MaintenanceRequest
Level 2 Process Control
Maintenancedefinition
management
MaintenanceDefinition
Maintenance Operations
Relationship with MRO for Asset Management– Maximo
MIMOSA – Vendor consortium to
exchange asset data– Goal is to enable the
exchange of asset and maintenance data between different vendors system
OPC is the preferred transport for maintenance dataWhen ISA-95 Maintenance Operations standard is completed B2MML will be expanded to support maintenance data
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Quality TestResource
Management
Quality TestCapability
Quality Performance
Analysis
Quality TestData
Collection
Quality TestExecution
Quality TestDispatching
Quality TestTracking
Quality TestResponse
DetailedQuality TestScheduling
Quality TestRequest
Level 2 Process Control
Quality TestDefinition
Management
Quality TestDefinition
Quality Operations
Quality operations centered around Laboratory Information Systems (LIMS) Key production data moved to Exaquantum/Batch– Part of permanent
batch record– Assembled into B2MML
Production Response
OPC is the preferred transport for LIMS dataWhen ISA-95 Quality Operations standard is completed B2MML will be expanded to support quality data
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
InventoryResource
Management
InventoryCapability
Inventory Analysis
Inventory DataCollection
InventoryExecution
InventoryDispatching
InventoryTracking
InventoryResponse
Detailed InventoryScheduling
InventoryRequest
Level 2 Process Control
InventoryDefinition
Management
InventoryDefinition
Inventory Operations
Inventory operations centered around Warehouse Management Systems and ERP material managementCustom integration ofinventory systemsOPC is the preferred transport for inventory dataWhen ISA-95 Inventory Operations standard is completed B2MML will be expanded to support inventory data
Yokogawa ISA-95Copyright © Yokogawa Electric Corporation>April 8, 2005
Summary
Yokogawa believe ISA-95 is a valuable standard for the industryWe are committed to continuing to support its development and adoptionISA-95 is Yokogawa’s preferred format for:– Enterprise-Control System Integration– Level 3 (MES) System Integration
B2MML (Business To Manufacturing Markup Language) is Yokogawa’s preferred means for implementing ISA-95– Adopted by leading manufacturing companies– Mainstream information technology
ISA-95 implementations require careful planning and customized implementation
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