Mfg. Operations Standards Need to Converge into a Manufacturing Application Integration Framework Charlie Gifford Director Lean Production Management.

Mfg. Operations Standards Need to Converge into a

Manufacturing Application Integration Framework

Charlie GiffordDirectorLean Production Management

Agenda

“What are the tough implementation problems (infrastructure, standards) that must be solved to

make “smart assembly” a reality?”

1.State of 21st Century Plant and Production Mgt. Technology

2.Challenges for B2M and B2B3.Interoperability Maturity Model 4.Significant Events in Mfg Operations Standards 5.What is Business-to-Manufacturing Integration?6.A View into an Evolving Manufacturing Application

Framework5 minutes of Discussion

GE’s Standards Liaison for Manufacturing Operations

Charlie Gifford, Director of Lean Production Management

–Chairman, ISA95 Best Practices Working Group–Chairman, ISA95 Part 4 Quality Test Ops Mgt Working

Group–Voting Member, ISA88 & ISA95 Committee–ISA95 Representative, ISA95/SCOR Alignment Working

Group–Information Member: ISA99–GE Representative, Mfg Interoperability Guideline

Working Group–GE Representative, MESA Technical Committee–Director, ISA Computer Technology Division 97-99–GE Representative, SCOR MAKE Committee–Chairman, Editorial Board, Industrial Computing

Magazine 98-02–Published over 35 papers on Industrial Computing–Standards Work: ISA84, 88, 95, MESA, SCOR, Many DOD

Standards

20th Century Manufacturing Flow

Aligning Mfg. Capabilities to 21st Century Challenges Mandates

Change…

Customers

Manufacturers Dist

Supplier Exchanges

Customer Exchanges

LogisticsExchanges

Suppliers

CMs

Retailers

Virtual Mfg.

Logistics Providers

Copyright @2004 AMR Research: All rights reserved.

Business Evolves into Configurable Demand-Driven Supply Chains

DC

DC

DC

DC

DC

Customer

Customer

Customer

Customer

Customer

CustomerDC – Dist. Channel

Need:ProductionCapability

Supplier

Supplier

Supplier

Supplier

Plant

Plant

Plant

Copyright @2004 AMR Research: All rights reserved.

Evaluate: Customer Value + OTD + Configured Production Capability = Profit

Margin

Copyright @2004 AMR Research: All rights reserved.

CM

CM

CM

Plant PlantCM

CM

DCsPlant

Plant

Loosely coupled capacity based on profit/value ratio or

compromise between value chain (profit) and

stream (demand)

Plant

Plant

Plant CM

CM

CM

Plant PlantCM

CM

DCsPlant

Plant

Loosely coupled capacity based on profit/value ratio or

compromise between value chain (profit) and

stream (demand)

Plant

Plant

Plant

Plant

Plant

Plant

21st Century Manufacturing Enablers:Flexibility & Real-Time Visibility

Challenges of B2M and B2B Communication and Processes

• Many different applications across the enterprise doing the same function

• No enterprise wide application and information architecture

• Several versions of “enterprise-objects” or language for Product, Customer, Order, etc.

BusinessLogistics

ManufacturingOperations

Challenges of B2M and M2M Integration

• Effective and Flexible Mfg. Operations…..HARD TO DO!• Various Forms of the MES / ERP solution:

Industry-specific production types Mixture of work order types across plant Speed and Volume of Throughput

• Standardization of work flow “best practices” Must Allow Change in Production Processes

Without requiring change in logistics system Provide a clear demarcation of MES / ERP

responsibilities and functions

Technology S Curve: Challenge Explained

MES / PM

HMI / SCADA / PLC

Also Applies to Methods Development: Delivery, Training, User, Support and Change disciplines

ERP

SCM

2006 Top Strategic Platform Investments Focus on Mfg Operations!

5%

3%

15%

21%

9%

11%

39%

4%

12%

22%

10%

14%

34%

3%

Customer Management

Product Lifecycle Management

Sourcing and Procurement

Supply Chain Management

ManufacturingOperations

Desktop software

Most Important (n=442) Largest Dollar (n=439)

Source: AMR Research 2006 IT Spend Survey

ERP

Interoperability Maturity Models Applied to Logistics and Operations

Systems•Level of Information System Interoperability (LISI) –Framework scopes connectivity level for technical interoperability–Does not account for system response required for mfg. workflows

Dept. of Defense

Efforts Now on How to Model Systems to Business Process Before

Going Live

• Levels of Conceptual Interoperability Model (LCIM) provides a framework for planning your data before modeling your application

Virginia Modeling, Analysis & Simulation Center Old Dominion University

Build Single Schema to Accelerate

Lean Manufacturing Transformation Road Map

Standardization Effect of Mfg. Application Framework

•Standardization Effect•S =Standardization• I = Improvement•Key elements behind standardization are:

• Takt time scheduling• Standard Work towards

single schema & process

• Route & Recipe verification process

• Change mgt. process

Effect of ISA95 together with Lean process and 6 Sigma production improvements

Lots of Standards Convergence Activity: 10+ Years of Work Moves

toward Product

OMACSP-88

Dennis Brandl

Supply Chain/ SCOR(4)(5)

1 2 3 4

SP-95Keith Unger

(3)(4*)

1 2 3

WBFCraig Wilkins

(1)(2)(3)(4*)

IEC6151362264

SP-99(cyber security)

Byran Singer

OAG /OASIS(3)(4)

MIMOSA(3)(4)

OPC(0)(1)(2)(3)(4)(5)

CIDXMake2Pack

Dave Chappell(1)(2)

Process Standards (ISA, IEC, ISO, ANSI)

Tech.Reports

5 6S88-S95

Lynn Craig

B2MMLEmersonBrandl

BatchMLEmersonBrandl

Machine Standards

Packagaing Workgroup

SC654 5 JWG15

ISO

S88 Part 6Thomas

Nash

OMAC-ISA ActivityOMAC

Manufacturing Infrastructure

OMAC Architecture

Group

Microsoft Man. Users Group

Machine Tool HMI-API

Step-NC

Packagaing Workgroup

PackConnect

Rick VanDyke

PackSoft

Gerd Hoppe

PackAdvantage

Bill Henderson

PackML

Fed PutnamMike Lamping

PackLearn

Dr. Ken Ryan

Make2Pack

Dave Chappell

ExecutiveCouncil

Numerous

Technical Director

Dave Bauman

OAGIS, SCOR

Level 3: Manufacturing Operations

Level 4+: Enterprise

Level 5+: Inter-Enterprise

Levels 2, 1, 0: Machine / Plant Work

OPC: DA, HDA, A&EOMAC

Discrete Process

OAGIS, SCOR

MIM

OS

A

ISA

-99

OP

C U

A ISA-95

ISA-88B2MMLOAGIS

An Integration Evolution: MIG WG Manufacturing Domain Mapping

F O U N D A T I O N

Hybrid

•Data Modeling: Real-Time Data Aggregation vs. Business Process Transactions

Business Planning & Logistics

Plant Production Scheduling,Operational Management, etc

Manufacturing Operations Management

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

BatchControl

DiscreteControl

ContinuousControl 1 - Sensing of production work process,

manipulate the production work process

2 - Work unit (operation): Monitor, supervisory control and automated control of the production work process

3 - Work Unit and Flow Defined. Work flow / recipe control produces desired end products. Analyzes Work Data, Maintains records and optimizes the production process.

Time FrameDays, Shifts, hours, minutes, seconds

4 - Establishes the basic plant schedule - production, material use, delivery, and shipping. Determines inventory levels.

Time FrameMonths, weeks, days

0 - The actual production work process

ISA-95 & Purdue Hierarchy Model Defines MOM and ERP+ Domains for Information

Exchanges

ISA 95.01, .02, & .05 Standards

ISA 95.03, .04 & .06 Standards

Manufacturing Application Framework and Transformation Methodology

From ANSI/ISA-95.00.01-1995 Copyright ISA 2006. Used with permission. www.isa.org

Company Production Canonical Schema

Information Data

Model, Objects andDefinitions

Domain Definitions

Metrics ConstructionCategories

forInformation Analytics

Functional Segregation & Metrics

by Scenarios and Domain

Functions & Data Flowsof Interest

Supply Chain & Mfg. Scenario &

Metrics

Manufacturing Use Case

Metrics Customer Supplier

ProcessPurchaseOrder

AcknowledgePurchaseOrder

ShowDeliveryReceipt

ProcessInvoice

ConfirmBOD

Use Cases and Transaction Set Construction

QA

ServiceR&D InboundLogistics

- Mfg.Ops.

ProductionPackage

Inputs(Supplier)

Conversion(Mfg.)

DistributionConsumer

MaterialPrep

Out- boundLogistics

Mkting& Sales

Assembly

ISA-95 Functional Enterprise-Control Model

Procurement(5.0)

ProductionScheduling

(2.0)

Material andEnergy Control

(4.0)

ProductInventory

Control(7.0)

Product CostAccounting

(8.0)

QualityAssurance

(6.0)

ProductShipping Admin

(9.0)

OrderProcessing

(1.0)

ProductionControl

(3.0)

MaintenanceManagement

(10.0)

ResearchDevelopment& Engineering

Marketing& Sales

ISA S95 Part 1&2

From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org

ISA 95: 4x4 Object Model Defines Production Work for B2M Data

Exchanges

People MaterialsEquipment

Resources

Segments

Structure / View

Production Schedule

Production Performance

Production

Product

Time

Production Capability

Capability

Product Definition

Product

4 Resource Categories 4 Information Categories

From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org

First, Lets Understand Primary Drivers for MOM / ERP+ Segregation Requirements

Work Flow Complexity Matrix

Production TypesDiscrete Manufacturing Batch ProcessingContinuous ProcessingWork Order TypesEngineer-to-Order (ETO)Make-to-Order (MTO)Make-to-Stock (MTS)

9 Mfg. Scenarios (with hybrids) of Production and WO Types

Each have a specific set of business processes and rules Contributors: Legacy, Speed, Volume, Size, Compliance,

SKU Count

Packaging &Assembly

Production

Mtl. Prep

Complexity

Interoperability Interface Depends on Production Environment, Industry,

Products…

ProductionResource Mgt.

ProductionPerformance

Analysis

ProductionData Collection

ProductionExecution

ProductionDispatching

Productiontracking

DetailedProductionScheduling

Level 2 Process Control/ Plant Work

ProductDefinition Mgt.

ProductionCapability

ProductionPerformance

ProductionSchedule

ProductDefinition

P-MTS

P-MTS

B-MTO

D/B-ETO

B/P-MTO

From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org

System Function Segregation & Interoperability

Determines Lean Performance

B2M

Level 2: Plant Work

Maintenance Production Quality Test Inventory

UProduction

datacollection

Productionexecution

Productionresource

management

Productiondispatching

Productiontracking

ProductionPerformance

Detailedproductionscheduling

ProductionSchedule

Productdefinition

management

Productionperformance

analysis

ProductionCapability

ProductDefinition

Maintenanceresource

management

MaintenanceResponse

Detailedmaintenancescheduling

MaintenanceRequest

Maintenancedefinition

management

MaintenanceCapability

Maintenanceanalysis

MaintenanceDefinitions

Maintenancedata

collection

Maintenanceexecution

Maintenancedispatching

Maintenancetracking

Inventory resource

management

InventoryResponse

Detailedinventoryscheduling

InventoryRequest

Inventorydefinition

management

Inventoryanalysis

InventoryCapability

InventoryDefinitions

Inventorydata

collection

Inventoryexecution

Inventorydispatching

Inventorytracking

Qualityanalysis

Qualitytest resourcemanagement

Quality TestResponse

Detailedquality testscheduling

Quality TestRequest

Qualitydefinition

management

Quality TestCapability

QualityDefinitions

Qualitytest datacollection

Quality testexecution

Quality testdispatching

Quality testtracking

Manufacturing Application (Use Case) Framework (MAF)System Architecture Must Support Continuous ImprovementMust Allow Change in Production Processes Clear demarcation of MOM / ERP+ responsibilities & functions

ISA 95.03 “- Part 3: Activity Models of MOM”

Level 4+: Extended Enterprise

From ISA-95 Copyright ISA 2004. Used with permission. www.isa.org

• Mostly at the data level• Mostly point to point• Custom program interfaces

or flat file exchange• Grows at exponential rate

Current State of Integration

Integration Technology Evolves From Data to Process Level Capabilities…

Enterprise

Application

Integration

Object Brokers

Workflow

DataReplication

& File

Transfer

Application Servers

MessageOriented

Middleware

Point to

Point (Custom)

BusinessProcess

Management

Continually Evolving

ExtractTransform

Load (ETL)

Web Services

Service

Oriented

Architecture

Enterprise

Service

Bus

Integration Architecture Patterns

© CSC 2005 All rights reserved.

BUT….Semantic Layer in Integration is Lagging

• Interoperability requires interfaces to be standardized. Only 5% of the interface is a function of the middleware. The other 95% is a function of the application semantics. (Gartner Group)

Application Integration Semantics

Messaging and Transport Services

95%

5%

Domains Addressed• eCommerce 10 Years in the

Field• Manufacturing• Logistics• CRM• ERP

70 Business Scenarios, 434 Messages (BODs) 77 Nouns (Common Objects) & 12 Verbs

Defined 7 Workgroups of new Content More localization for more International

support UN/CEFACT/ISO compliant ISO 11179, CCTS 2.01/ISO 15000-5, TBG17

BIE/ABIE

OAGIS® 9.0 Scope Provides Business Semantics

OAGIS B2M Integration: ISA95/OAGIS Convergence

Plant Functions

Product Definitions and Production Capabilities

Production Orders WIP and Inventory Status

Order Completion & Resource Consumption

BODS Sync/Get/Show ItemMaster

Sync/Get/Show Production Order

Get/Show/Update Inventory Count

Get & Show Consumption

Sync/Get/Show Inventory

Sync/Get/Show Routing

Get/Show/Confirm Inventory Issue

Allocate Costing Activity

Sync/Get/ShowUnit of Measure Group

Sync/Get/Show Dispatch List

Issue/Receive Inventory Movement

Update Inspection

Sync/Get/ShowBill Of Material

Sync/Get/Show Maintenance Order

Get/Show/Update WIP Confirm

Get/Show/Confirm Inventory Issue

Get/Show/Sync Engineering Change Document

Sync/Get/Show Planning Schedule

Process WIP Merge

Issue/Receive Inventory Movement

Sync/Get/ShowEngineering Work Document

Sync/Get/Show Sequence Schedule

Process WIP Move Show Shipment Schedule

Sync/Get/Show Planning Schedule

Sync/Get/Show Employee Schedule

Process WIP Recover

Show Shipment

Sync/Get/Show Sequence Schedule

Process WIP Split Get/Show/Update Picklist

Sync/Get/Show Inspection

Get/Show WIP Status

Time & Attendance

MAF Best Practice Transformation Methodology

Utilizes ISA95 with other Models throughout Best Practices ISA95/MESA BP Working Group: Book 1.0, December 2006 Step 1: (Define) Train Staff on Technical Applications used to benchmark & design

business process in Methodology (Steps 2-4) Step 2: (Define, Measure, Analyze) Structured Mfg. Ops. Assessment and Schema Migration PlanStep 3: (Analyze, Improve, Control) Accelerated MOM Application Implementation & TransformationStep 4: (Analyze, Improve, Control) Life Cycle Management of MOM Application, Interfaces & Metrics

Smart Assembly Need Methods for Schema, Process, & Lean 6 Sigma

Transformations• Interoperable MOM / ERP solutions require consistent:

• Production Data Model and Schema based on Work Definition

• Functional and Data Exchange Models• Consistent Message Structure from M2B and B2M• Methodology for MOM / ERP integration

• Single Production Schema Reinforces Lean practices such as: Standard work flow practices across MOM Activities:

Production, Quality, Maintenance, & Inventory Operations Schedule/Dispatch, Data entry methods, CID, ECO,

Routes, etc.Cross-training operators and mechanics:

Common work definition for operations and resourcesSingle XML production schema across all MOM

applications simplify Data Collection, Analytics, Interfaces and Reporting

Questions?

Charlie Gifford [email protected] Performance Mgt. GE Fanuc AmericaChairman, ISA-95 Best Practices Working Group