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ISA 95 - how and where can it be applied

Conference Paper · October 2004

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 ISA 95 - how and where can it be applied?

Charlotta Johnsson
Lund Institute of Technology
Department of Automatic Control
Box 118, 22100 Lund, Sweden
Email: [Link]@[Link]
Phone; +46 46 222 8783
Fax: +46 46 138118

KEYWORDS

ISA 95, manufacturing execution, manufacturing operations systems, design, specification

ABSTRACT

Many of you have certainly heard about the ISA 95 standard, and you know that it treats the subject
of how Enterprise systems should be integrated with manufacturing and control systems, but do you
know how and where it can be applied?
Almost anyone, in some way connected to the control, automation and manufacturing operations
field can benefit from knowing its content; vendors, end-users as well as integrators, technicians,
operators as well as managers and CEOs.

This paper will shortly present the ISA 95 standard and describe the benefits of knowing and
applying it for different categories of people.

NOTE: The paper contains some figures from standard ISA 95, Enterprise-Control System
Integration. Copyright ISA.
1. INTRODUCTION
The development of the ISA 95 standard started in 1995. Even though this is a few years back, the
interest in the standard is continuously increasing and its content is still relevant and valid. The
standard is entitled “Enterprise-Control System Integration”, and as the title indicates, the standard
treats the topic of how Enterprise/Business systems should be integrated with Manufacturing and
Control systems. The standard currently consists of 3 parts, with an additional two parts under
development.

The standard is being used by the vendor community as well as of the end-user community and
integrators. This paper will start with a brief introduction of the standard itself [1], and will continue
with some examples of how it is and/or can be used within the different disciplines.

2. ISA 95
Industrial systems can generally be divided in different functional categories depending upon its
focus. ISA 95 is based upon the hierarchical structure presented in the The Purdue Enterprise
Reference Architecture (PERA) [2]. This hierarchy defines 4 different levels, see figure 1 (see also
figure 3 in ISA S95 Part1).

Level 4
Business Planning & Logistics
Plant Production Scheduling,
Operational Management, etc
Interface addressed
Interface addressed in Part 1
in Part
and Part1 2ofofthis
the standard
Level 3 standard
Manufacturing
Operations & Control Activities defined in Part 3
of the standard
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...

Levels
2,1,0
Batch Continuous Discrete
Control Control Control

FIGURE 1. Functional model

Level 4 corresponds to the Business Planning and Logistics and this is where activities like plant
production scheduling, operations management etc are taken care of. Level 3 is the Manufacturing
Operations and Control level, the activities within this level are e.g., production dispatching,
detailed production scheduling, reliability assurance etc. Level 4 and level 3 are similar
independently from the type of industry they are used in. Level 2 corresponds to the process control
systems, level 1 to the sensors and actuators, and level 0 is the production process itself. Level 2, 1

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]
and 0 differs with respect to the type of industry – batch, continuous and/or discrete – they are used
in.

Figure 2 (see also Figure 5 in ISA 95 part 1) shows the functional enterprise-control model. The
wide dotted line illustrates the boundary of the enterprise-control interface. The manufacturing
control side of the interface includes most of the functions in production control and some of the
activities in the other major functions. The labeled lines indicate information flows of importance
to manufacturing control. The functions included in the Enterprise side of the interface, i.e, the
functions involved in a business planning and logistics system are shown on the outside of the wide
dotted circle. A description of each function, together with a list of sub-functions, is given in the
standard.

Order
and
rial Processing
m ate ipt rs
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In ener n O (1.0) Product Cost Product
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y Accounting Shipping Admin
Pr ab
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A
Finished Goods Inventory
Production

Release to ship
Confirm to ship
t
os

Scheduling Pack Out Schedule

dc

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Short Term Material

W
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Material and and Energy Requirements Production Process Data Product

er

Energy Control Control In Process Waiver Inventory Control

(4.0) Material and Energy (3.0) StaRequest (7.0)
nd
Inventory ard
Re s an
Inc er
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FIGURE 2: Functional enterprise-control model

The three parts of the ISA 95 standard, each with its own subtitle, treat different parts of the
Enterprise-Control systems integration issue. The focuses of the parts are shown in Figure 1.
Part 1: Models and Terminology
Part2: Object Model Attributes
Part 3: Activity Models of Manufacturing Operations Management

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]
2.1 ISA 95 Part1
ISA 95 Part 1 defines the categories of information that should be exchanged between the Business
System and the Manufacturing Operations System. 4 categories are defined;
• Product Definition
• Production Capability
• Production Schedule
• Production Performance

The four categories of information are shown in Figure 3 (see also figure 3 in ISA 95 Part3
(daft15)). NOTE: in ISA 95 part1, the two categories Production Schedule and Production
Response were combined into one category referred to as Production Information.
Each of these 4 categories relies on 4 resources, defined in ISA 95 Part 1.
• Personnel
• Equipment
• Material
• Process Segment

Business planning &

logistics information
Plant production scheduling,
operational management, etc

Product Production Production Production

definition capability schedule response
information information information information
(What must be (What resources (What to (What was
defined to make are available) make and use) made and used)
a product)

Manufacturing operations &

control information
Production operations, maintenance
operations, quality operations, etc

FIGURE 3: The 4 categories of information as defined in ISA 95 part1.

The content of each one of the 4 categories and the 4 resources are specified through object models.
The object models are defined in ISA 95 Part 1 and are presented using UML (Unified Modeling
Language) notation.

2.1 ISA 95 Part2

ISA 95 Part 2 further defines the attributes for each of the objects contained in the object models.
Thanks to the UML notation, the object models are software independent. They contain a
description of the interface content i.e., the data to be exchanged between the Business System and
the Manufacturing Operations System.
Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.
Presented at ISA Expo 2004; http:/[Link]
Figure 4 shows a part of the object model of the “Production Performance” (the entire object model
is shown in Figure A1 in Annex A). The figure contains three objects; production performance,
production response and segment response, it also contains information about how these objects are
related. As indicated in the figure, a production performance should be given in terms of one or
many production responses; a production response is given in terms of one or many segment
responses, etc. Each object in the object model has an associated set of attributes; these are
presented in ISA 95 part2.

Production
Performance

Is made up of
1..n
May Correspond Production
to a
Response

Is made up of
1..n
Corresponds Segment
to a
Response

May contain

FIGURE 4: part of the object model of the Production Performance

The attributes associated to the Production Response object are shown in Figure 5.

Attribute Name Description Example

ID A unique identification of the production performance and could include version 1999-10-27-A15
and revision identification.
The ID shall be used in other parts of the model when the production
performance needs to be identified.
Description Contains additional information and descriptions of the production performance. “Production performance
report on Oct 27, 1999
production schedule.”
Production An identification of the associated production schedule, if applicable. 1999-10-27-A15
Schedule Production performance may not relate to a production schedule, it may be a
report on all production for a specific time, or reported on by plant floor events.

Start Time The starting time of the associated production performance, if applicable. 10-28-1999

End Time The ending time of the associated production performance, if applicable. 10-30-1999
Published Date The date and time on which the production performance was published or 10-27-1999 13:42 EST
generated.
Location An identification of the associated element of the equipment hierarchy model. East Wing Manufacturing
Line #2
Element Type A definition of the type of associated element of the equipment hierarchy model. Production Line
For example: enterprise, site, area.

FIGURE 5: Attributes for Production Performance

2.3. B2MML

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]
Having software independent description like UML is very useful, but in a real application, it is
even more useful to have a technical solution for how to exchange the information between the
Business system and the Manufacturing and Control system. B2MML stands for Business to
Manufacturing Markup Language and it is a XML translation of the object models defined in ISA
95. Figure 4 shows a part of the B2MML schema for Production Performance.

<xsd:complexType name = "ProductionPerformance">

<xsd:sequence>
<xsd:element name = "ID" type = "IDType"/>
<xsd:element name = "Description" type = "DescriptionType"
minOccurs = "0" maxOccurs = "unbounded"/>
<xsd:element name = "Location" type = "LocationType"
minOccurs = "0"/>
<xsd:element name = "PublishedDate" type = " PublishedDate Type"
minOccurs = "0"/>
<xsd:element name = "ProductionScheduleID" type = " ProductionScheduleIDType"
minOccurs = "0"/>
<xsd:element name = "startTime" type = " startTimeType"
minOccurs = "0"/>
<xsd:element name = "EndTime" type = "EndTimeType"
minOccurs = "0"/>
<xsd:element name = "EquipmentElementLevel" type = " EquipmentElementLevelType"
minOccurs = "0"/>
<xsd:element name = "ProductionResponse" type = "ProductionResponseType"
minOccurs = "0" maxOccurs =
"unbounded"/>
<xsd:ant namespace=”##any”
minOccurs = "0" maxOccurs =
"unbounded"/>
</xsd:sequence>
</xsd:complexType>

FIGURE 6: B2MML schema for Production Performance

Theoretically, it should be possible to let the manufacturing/control system fill in the information
regarding the Production Performance and send it to the business system, this, of course, only holds
if both systems are compliant with the ISA 95 standard and if both systems supports XML.

2.4. ISA 95 Part 3

ISA 95 Part 3 focuses upon the activities within the Manufacturing Operations, i.e., within level 3,
see figure 1. This part specifies a generic activity models that applies for different types of
Manufacturing Operations such as production, maintenance, inventory and quality. The activity
model for Production Operations is shown in figure 7 (see also Figure 8 in ISA 95 part3, draft 16),
each activity is represented as one oval. The tasks within the activities are described in the standard.

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]
 Product Production Production Production
definition capability schedule performance

Detailed
production
scheduling

Production
Production
resource
tracking
management

Production
Production
Performance
dispatching
analysis

Product Production
definition data
management collection

Production
execution

Equipment and process Operational Operational Equipment and process

specific production rules commands responses specific data

Level 0-1-2 Process control

FIGURE 7: Production Operations

The four arrows in the top of the figure identify the data to be exchanged with the Business system.

As stated in the standard: the generic activity model and the specific models are not intended to
represent an actual implementation of a manufacturing information system. Neither is it intended to
show how an organization should be structured.

3. BENEFITS
So, how can this standard be beneficial for you, as an integrator, software producer (vendor) or
software user (end-user)?

3.1 Common benefits

The most obvious benefit is, of course, that a set of common terms and terminology is defined.
Employees working at the Business level (i.e., SAP, Baan, JDE etc) can start to communicate with
the Manufacturing and Control people. Traditionally, the two groups have used different words for
the same thing, or called the same thing different names, resulting in misunderstandings and
unnecessary time-delays and errors. Technicians, operators, managers and CEOs can now better
understand each other. And people from different companies, now have a common set of
terminologies to use when speaking with each other.

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]
The standard has been developed by a large group of people with different backgrounds, working
with different aspects of the Enterprise-control system integration topic. The collective knowledge
of this group is unbeatable and there is no need to “reinvent the wheel”. What this group has agreed
upon is probably the best solution concerning models and terminology to be successfully used.

ANSI/ISA standards are only valid in America. However, the ISA 95 standard is now under
evaluation by International Electrotechnical Commission, IEC, and by International Standardization
Organization, ISO, in order to become international standards. The corresponding standard will be
named IEC 62264.

3.2 Vendors
A company that develops and sells a product is considered a vendor. Vendors of Business Systems
and/or Manufacturing Operations/Execution systems are concerned with the ISA 95 standard. There
are many aspects associated to ISA 95 that a vendor can take in to consideration and benefit from
when developing, marketing and selling their product.

• ISA 95 provides a good understanding of the Enterprise/Control systems integration issue as

well as of the MES/MOS field. It is therefore a good knowledgebase for each developer,
system architect as well as product manager to have. The standard provides a good platform
on which necessary and required discussions can be based.

• Vendors can with advantage follow the terminology defined in ISA 95 part1. Each
developer should have access to the full description of the words that he/she is concerned
with in the development of his/her part of the product. This has the advantage of getting a
well defined and consistently used terminology in the product.

• Most MES/MOS products and Business systems has a built-in model of the plant. ISA 95
part 1 defines an equipment model that can be used as a basis for designing the plant objects.
If object-oriented programming is used, the equipment objects shown in the equipment
hierarchy can each be a class from which sub-classes can be derived.

• ISA 95 part 3 does not intend to define how a product should be designed. However, this
part of the standard is excellent to use a reference when discussing what functionalities are
covered by the MES/MOS product. Some of the activities, e.g., scheduling, or data
collection, might not be included in the MES/MOS product itself, but might be covered by
another product from the same company.

• ISA 95 part 2 presents the object models and the associated attributes. These models can be
used in the database of the product. This makes it easy to construct a ISA 95 compliant
interface and/or to support the B2MML schemas.

• In IEC 62264 part 2, i.e., in the international version of the ISA 95 part2 standard, a section
is dedicated to the definition of Completeness, Compliance, and Conformance

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]
3.3 End-Users
A company that uses and buys a product is considered an end-user. End-users of Business Systems
and/or Manufacturing Operations/Execution systems are concerned with the ISA 95 standard, [5].
There are many aspects associated to ISA 95 that an end-user can take in to consideration and
benefit from when buying, evaluating and using a product.

• An automation project can consist in integrating a Business/Enterprise system with a

Manufacturing Operations systems. In such a project one important task is to identify and
define the scope of the Enterprise and manufacturing operations to be automized. All the
operations/activities/tasks might not be identified, defined or even understood. The ISA 95
Functional Enterprise-control model, see figure 2, can be used as a starting point to localize
the functions and the data flows involved in the automation project.

• An end-user sometimes has to compare the products of different vendors. The vendors often
present the capabilities and functionalities of their products in different ways. In order to get
a good comparison and a good understanding of the different product, a good idea is to use
the ISA 95 standard as a “universal language”, i.e., to translate the presentation of a vendor
into ISA 95 terminology and then compare.

• For each function figuring in the functional enterprise-control model (see figure 2) a list of
sub-functions is given. An end-user can benefit from this list by explicitly asking their
different prospective vendors to specify which of the sub-functions they have covered by
their products, in which product this function is contained and what it is named “in the
language of the vendor”. The answers given by the different vendors can easily be
compared.

3.4 Integrators
Integrators are often involved when selecting a solution and when implementing the solution. In
order to select a good solution it is necessary to have a good understanding of what functionality is
needed and exactly what is expected from this functionality. Integrators therefore often have to
analyze the user requirement specification very carefully. The standard can help structuring the
work that the integrator has to make in order to successfully select a solution for MES.

• The very first task is to understand if the function the client is asking for is a function
belonging to the Manufacturing Operations domain, or a function residing in the Enterprise
system, or a function involving both systems. The functional enterprise-control model
(Figure 2) gives a guideline for where different functions reside.

• If the integrator is concerned with requirements residing in the Manufacturing Operations

domain, the standard can be used further, especially ISA 95 part 3 is of relevance. The
requirements can be classified as belonging to production, maintenance, quality and/or
inventory.

• Often an integrator is concerned with requirements that involve characteristics from

production operations, maintenance operations, quality operations as well as from inventory
operations. The requirements belonging to each of these groups can be further penetrated
Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.
Presented at ISA Expo 2004; http:/[Link]
 and classified according to the activities of the operations model, e.g., detailed scheduling,
dispatching, data collection etc, compare figure 7 (production operations model).

• When the requirement is fully classified according to ISA 95 and thereby fully understood,
it is much easier for the integrator to understand if some of the requirements can be merged
and provided by one and only one application component of if the requirements are better
implemented by different application components. The solution selection becomes much
easier. It is also much easier to get in contact and to discuss with different vendors when it is
known exactly what functionally is needed.

4. SUMMARY
The ISA 95 standard is about Enterprise-Control system integration. This standard can be used with
success by several different categories of people, vendors, end-users as well as by integrators. The
standard is not written explicitly for any of those categories of people, yet it contains a lot of
information and help for
• Vendors: designing and structuring a product
• End-users: structuring user-requirements and comparing products from different vendors.
• Integrators: understanding the user requirement specifications and selecting solutions
• As well as getting common terminology and models for the [Link] system
integration domain and the Manufacturing Operations Domain

This paper has briefly presented the ISA 95 standard and has listed some of the advantages that you
can benefit from by knowing its content.

REFERENCES
[1] Johnsson, C. and Schumacher, H., Communication through B2MML – is that possible?, 2004, WBF.

[2] Williams, T.J., The Purdue Enterprise Reference Architecture, A Technical Guide for CIM Planning and
Implementation, 1992, ISA, ISBN 1-55617-265-6
[2] ANSI/ISA 95.00.01-2000, Enterprise-Control System Integration Part 1: Models and Terminology, 2000, ISA

[3] ANSI/ISA 95.00.02-2001, Enterprise-Control System Integration Part 2: Object Model Attributes, 2001, ISA

[4] IEC/ISO 62264-1, Enterprise-control system integration - Part 1: Models and terminology, 2003, IEC.

[5] Ray Walker, Using ISA95 to Automate manufacturing Operations (ppt-presentation), Presented at PlantSuccess
2003 Northeast.

Copyright 2003 by ISA - The Instrumentation, Systems and Automation Society.

Presented at ISA Expo 2004; http:/[Link]

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