Process Systems Engineering

Course Code: IEng515

ETHIOPIAN INSTITUTE OF TECHNOLOGY- MEKELLE [EiT-M]

DEPARTMENT OF INDUSTRIAL ENGINEERING
Course Instructor: Teklay G. [Msc]
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 Course objective
• To provide basic understanding of process
systems
• To enable students practice to develop models
of existing process (“AS-IS”) and transform
them to process models with some
advantages (“TO-BE”) using the different
approaches and methods.

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 Fundamentals of Process modeling
• Outline
• Introduction
• Existing Process Modeling methodologies
• Integrated Definition Methodology
• Collecting Information
– Group Meeting Method
– Interview Method
– Comparison of Information Collection Methods
• Model Building Case Study
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 What is process?
• In engineering, a process is a set of
interrelated tasks that, together, transform
inputs into outputs.
• These tasks may be carried out by
people, nature, or machines using
resources; so an engineering process
must be considered in the context of the
agents carrying out the tasks, and the
resource attributes involved.

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 Cont…
• Process engineering focuses on the
Design
Operation
Control
Optimization
• It covers a vast range of industries, such as
Chemical
Mineral processing
Advanced material
Food
Pharmaceutical
Biotechnological industries.
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 Systems engineering
• Is an interdisciplinary field of engineering that
focuses on how to design and manage
complex engineering projects over their life
cycles. Deals with
Work-processes
Optimization methods
Risk management tools in such projects.

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 System model
• Is a model that describes and represents a system.
• Building a model requires abstraction.
• Its purpose is to make a particular part or feature easier to
– Understand
– Define
– Quantify
– Visualize, or
– Simulate
• Using different types of models for different aims, such as
 Conceptual models to better understand
 Operational models to operationalize
 Mathematical models to quantify, and
 Graphical models to visualize the subject
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• EXAMPLE
• Manufacturing process
• Design process
• Business process

Types of processes:
• structured, e.g., manufacturing
• unstructured, e.g., healthcare
• deterministic
• stochastic
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Abstraction for Business process modeling
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 “AS-IS” and “TO-BE” model

• A process model created through a modeling

effort, referred to as “as-is” model, needs to
be transformed into “to-be” model that meets
the goals of the reengineering effort.

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 “AS-IS” model
Goal : to describe and understand the existing situation

• Description of the system (current situation) in such a way

that the kind of system and its behaviour can be studied and
understood
• Particularly useful for :
Specification
Analysis
Diagnosis

• Validity (does it conform with reality?) of the model is crucial

and should be checked
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 “TO-BE” model
Goal : to understand new situations

• A description of a new situation for the system

• particularly useful:
– To describe alternative solutions to problems
perceived
– To analyse potential solutions
– To explain and demonstrate favourable
alternatives to the problem owner

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Process analysis tool

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 Existing Process Modeling
Methodologies
They vary in scope, appearance, and theoretical foundations.
Computer Integrated Manufacturing - Open Systems Architecture
(CIM-OSA)
EXPRESS
GRAI Method
Integrated Enterprise Modeling (IEM)
Problem Statement Language/Problem Statement Analyzer
(PSL/PSA)
Structured Systems Analysis and Design Method (SSADM)
Object-Oriented modeling methodology for Manufacturing
Information Systems (OOMIS)
MOSYS (Modeling SYStem)
Petri Nets
IDEF Methodology 14
 IDEF Methodology
• IDEF Methodology
• IDEF = Integrated DEFinition

 IDEF methods have become widely used in

concurrent engineering (CE) efforts, total
quality management (TQM), and business
process reengineering (BPR) initiatives
 Concurrent engineering is the simultaneous and
integrated engineering of all design,
manufacturing, and operational aspects from the
conceptual formulation through project
completion.
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• IDEF0: modeling a wide variety of systems which use
hardware, software, and people to perform activities
• IDEF1x: to semantically model the relationships
between various pieces of data
• IDEF2: to capture the dynamic behavior of a system
• IDEF3: created specifically to model the sequence of
activities
• IDEF5: to model domain ontologies
• IDEF6: to define the motives that drive the decision
making process
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• An IDEF0 model consists of three components,
diagrams, text, and a glossary, all cross-referenced to
each other.
• Diagrams---box(represents function) and
arrow (represents interface)
• An interface may be input, an output, a
control, or a mechanism (ICOMs).

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• The IDEF3 process flow description is made up
of activities (units of behavior), links, and
junction boxes.
• Relationships between activities are modeled
with three types of links
– Precedence links
– Relational links
– Object flow links

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 • IDEF0 function box and interface arrows

o Inputs (I) enter the box and are

transformed by the function
o Exit the box as an output (O).
o A control (C) enters the box and
influences or determines the
function performed
o A mechanism (M) is a tool or
resource that performs the
function.
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• IDEF3 activity box and interface arrows
• Controls-- guide and influence the transformation
• Mechanisms are the resources (e.g., people, systems, or
devices) associated with performing the activity.

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• COMPARISON OF IDEF0 and IDEF3
• IDEF0 IDEF3
• FUNCTION ACTIVITY
• 4 ICOMs 3 (4) ICOMs
• No Logic Logical connectors

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• ICOM Example
• Part design: activity-x, diameter determination
• I = Part length
• C = Outcome of the design approval process
• M = Designer + CAD system
• O = Part diameter

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 • Standard Activity
Block
Wrong!
Avoid!

OK! Avoid!23
• Decomposition in IDEF3 methodology

Level 1

Level 2

Level 3

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 LOGIC JUNCTIONS
Symbol Meaning Definition

Synchronous INPUTS: All preceding processes must complete

& AND connector OUTPUTS: All following processes will start.

All inputs/outputs happen Asynchronously

Asynchronous INPUTS: All preceding processes must complete

& AND conector simultaneously

OUTPUTS: All following processes will start simultaneously.
All inputs/outputs have to happen at the same time
Synchronous INPUTS: One or more of the preceding processes must
OR connector complete
O OUTPUTS: One or more of the following processes will start
Any combination of inputs/outputs happens asynchronously
Synchronous INPUTS: One or more of the preceding processes must
OR connector complete simultaneously
OUTPUTS: One or more of the following processes will start

O simultaneously
Any combination of inputs/outputs can happen at the same
time
Exclusive OR INPUTS: Exactly one of the preceding processes must
complete
X
connector
OUTPUTS: Exactly one of the following processes will start
Exactly one of the inputs/outputs happens 25
 Example of IDEF3 process model

Activities: Units of behavior (UOBs)

Links: Relationships between activities which are of three types:
precedence links, relational links, and object flow links
Logic Junctions: AND (&), OR (O), and Exclusive OR (X)
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• Modeling objective:
– Value analysis – Value map, value model
– Cost reduction – Lean process model
– Quality/cost – Six sigma modeling
• Application area:
– Product development – Design process model
– Manufacturing – Manufacturing process model
– Supply chain – Supply chain (process) model
– Healthcare – Healthcare process model
• Model building approach:
– Kaizen event – Kaizen (generated) model
– Analyst – Analyst generated model
– Waste walk – Process model
• How to Build a Process Model?
– Left to right
– Right to left
– Top down
– Bottom up
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• Two approaches to information collection in
constructing process modeling

• Interview Method
• Group Meeting Method

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 Interview Method
Step1. Domain experts are informed about the process
modeling effort and provided with basic training in the
methodology
Step 2. Analyst interviews domain experts and produces a
high level process model
Step 3. Experts fill out the templates
Step 4. Analyst develops a draft process model
Step 5. Refinement of the draft model
- additional interviews
- group meetings

Activity

IDF3 Template 29
 Group Meeting Method:
Model Building Procedure
Step 1. Define scenario
Step 2. Identify and define appropriate activities
Step 3. Arrange activities in phased sequence
Step 4. Identify and define input and output objects
Step 5. Determine object life cycle states
Step 6. Determine decision points and flow
junctions
Step 7. Identify and define activity controls and
mechanisms
Step 8. Define notifications and messages.

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• Which method would you choose

• Interview?
• Group Meeting?

WHY?????

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 Characteristics of Methods
• Interview Method
• Low cost
• Short time
• Group Meeting Method
• Higher cost
• Longer time

Question ???
• When is it recommended use the interview
method and when the group meeting method?
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General Rule for Method Selection

• Interview Method Simple Processes

• Group Meeting
Method Complex Processes

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 Comparison of Techniques
Relationship between the number of domain experts
participating in the process modeling effort and the cost and/or
reliability of the information collected.

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 MODEL BUILDING CASE STUDY
• IDEF3 process model at level 1--process of inspection of
plastic labels

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Cont…
Premount process model (level 2)

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Cont…
Setup press activity process model (level 2)

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Cont…
Run press process model (level 2)

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Cont…
Operator process model (level 2)

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Cont…
Press clerk process model (level 2)

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 SUMMARY

• Understanding how to use a technique is often

more important than the technique itself
• An important attribute of a modeling technique is
it extendibility
• IDEF0 and IDEF3 are perhaps the simplest to use
and the easiest to extend
• The most frequently recognized shortcoming of
process modeling may be the lack of use and/or
incomplete analysis of models
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