Standards Certification Education & Training Publishing Conferences & Exhibits Automation Connections ISA EXPO 2006 Wed, 1:00 Oct 18.

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1 Standards Certification Education & Training Publishing Conferences & Exhibits Automation Connections ISA EXPO 2006 Wed, 1:00 Oct 18

2 Standards Certification Education & Training Publishing Conferences & Exhibits Design Patterns for Flexible Manufacturing: S88 and NS88 Dennis Brandl BR&L Consulting

3 ISA 88.01 is a standard, not an implementation There is more than one way to implement the standard This book contains a well defined and proven method for implementing the ISA 88 models in all types of industries

4 S88 & NS88 Design Patterns for Flexible Manufacturing Design Patterns S88 – A Design Pattern for implementing the ISA 88 models S88 Pattern for Automated Systems S88 Pattern for Manual Systems NS88 – A Design Pattern for implementing the ISA 88 models in non-batch systems Discrete Production Processes Continuous Production Processes Splitting and Merging Production Streams

5 Why S88 and NS88 Design Patterns? Over the past 10 years I have seen good, bad, and ugly implementations of the ISA 88 standards Some solutions stood out as much better than others The S88 and NS88 design patterns document the good patterns that lead to flexible, maintainable and extensible manufacturing control systems Answers questions such as: –What is an equipment module? –Where does the equipment phase execute? –What are the rules for defining a unit?

6 What is a Design Pattern? S88 and NS88 are design patterns derived from the ISA 88 standard and from implementations of the standard. A design pattern is not a design. A design can be transformed directly into code, instead a design pattern is a template for how to solve complex problems that applies to different but related situations. Design patterns mean that we do not have to solve every problem from “first principles”, but can instead rely on the experience of others who have come up with reusable solutions.

7 Procedural Control in a Recipes and Equipment Modules AddWater U1 Heat AddSugar XferOutHot U2 Coordination Control using Process Cell Configuration AddSyrup Mix-U1 Basic Control Control Modules MV PID SP CV ADD V1 V2 OUT Specifies what equipment to use for a batch and initiates the recipe’s procedural execution. Send commands to the basic control elements in the equipment Specify batch to be built Sends equipment states, modes, status, and resource availability to coordination control Mix-U2

8 Basic Control I/O Interface Equipment Procedural Control Recipe Procedural Control Control Modules Equipment Modules Unit Process Cell Process Coordination Control S88/NS88 Control and Equipment Hierarchies

9 PROCESS CELL UNIT Contains 1 or more Visible to the Recipe EQUIPMENT PHASE Contains 1 or more EQUIPMENT TAG Contains 0 or more CONTROL PARAMETERS REPORT PARAMETERS Contains 0 or more S88 – Recipe Side Defines the pattern for defining recipes Adds additional elements (equipment tag, report parameters) that are not defined in the ISA 88 standard

10 S88 Pattern for Automated Systems Defines More Detail than ISA 88 Contains 0 or more EQUIPMENT PHASE Implements 0 or more > PHASE/STATE PROCEDURE CONTROL STEP CONTROL ACTION Implements procedure for 1 or more phase states Contains 1 or more sends commands to > 0..1 0..n < Contains 0 or more shared equipment modules Contains 0 or more EQUIPMENT MODULE CONTROL MODULE UNIT PROCESS CELL 0..n1..n 0..n 1..n < Contains 0 or more shared control modules Uses status and state from > 0..n PHYSICAL EQUIPMENT 0..n 1..1 < Interfaces to EQUIPMENT PHASE (Unit) 1..n 1..1 Implements > 1..1 < Implements < Contains 0 or more shared or common control modules EQUIPMENT TAG < Contains 0 or more CONTROL PARAMETER REPORT PARAMETER 0..n

11 S88 Pattern for Manual Systems The Good Way to Implement Manual Control PHASE/STATE PROCEDURE CONTROL STEP interfaces to > 0..n References 0 or more MANUAL PHASE PROCEDURE UNIT PROCESS CELL 1..n CONTROL MODULE EQUIPMENT PHASE 1..n 1..1 Implements > 1..n Implements > 1..n 0..n Displays > PHYSICAL EQUIPMENT controls & monitors > controls & monitors > 0..n EQUIPMENT TAG 0..n Reports > CONTROL PARAMETER CONTROL ACTION REPORT PARAMETER

12 NS88 – Nonstop S88 Defines a pattern for handling product switchover without stopping production Applicable to Discrete and Continuous Production Allows the use of current commercial recipe execution systems Contains patterns for high speed manufacturing Contains patterns for production buffers Contains patterns for controlled startup and shutdown Contains patterns for simple and complex product switching systems (valve arrays, conveyor arrays) Defines an equipment state model for reusable equipment modules (derived form the Make2Pack models)

13 NS88 – Rules for Units A unit is only assigned to one batch at a time. Two units represent the actual physical equipment, a processing unit and a reporting unit, the physical equipment is under control of a shared equipment module The processing unit: –contains a single main processing phase that describes it primary function. –completes it’s main processing phase when the last element of the batch enters the unit. –keeps control of the old batch as it moves through the unit using the old batch’s processing requirements. –keeps track of the last element of the old batch as it moves through the unit. –keeps control of the new batch as it moves through the unit using the new batch’s processing requirements. –may send an end-of-batch signal to the next unit when the first element of the new batch exits of the unit. –may receive an end-of-batch from the previous unit when last element of the old batch enters the unit. The reporting unit … –phases complete when the last element of the batch leaves the unit. –reports on all elements of the batch processed through the unit. –records information on all elements of a new batch entering the unit.

14 NS88 – Generic Equipment Mode/State Model NS88 defines a generic equipment mode and state model that applies to a wide range of NS88 Units

15 EM-CS3 (Conveyor Switch) Feed 1 Feed 2 Storage S1 Storage S2 Storage S3 Storage S4 EM-CS4 Coat 1 Coat 3 Coat 2 Coat 4 Batch B1Batch B2 Batch B3Batch B4 RTS (B1) RTS (B2) RTR (B3) RTS (B4) RTR (B4) RTS (B3) RTR (B2)RTR (B1) EM-CS5 RTR (B1)RTR (B2) NS88 Handles Complex Product Switching in a simple manner

16 NS88 - Continuous Production Processes Pattern for control product switchover, startup, shutdown, and monitoring Rules for defining NS88 Units (where S88 does not apply)

17 S88/NS88 - Splitting and Merging Production Streams A common problem, but not addressed in ISA 88 An elegant pattern that allows the use of current commercial batch execution systems

18 S88 & NS88 Design Patterns for Flexible Manufacturing Design Patterns S88 – A Design Pattern for implementing the ISA 88 models S88 Pattern for Automated Systems S88 Pattern for Manual Systems NS88 – A Design Pattern for implementing the ISA 88 models in non-batch systems Discrete Production Processes Continuous Production Processes Splitting and Merging Production Streams

19 Standards Certification Education & Training Publishing Conferences & Exhibits Design Patterns for Flexible Manufacturing Questions?