ISA MOM CHRNCLS-2013 The MOM Chronicles ISA-95 Best Practices Book 3 0.pdf

1、THE MOM CHRONICLES: ISA-95 BEST PRACTICES BOOK 3.0by Charlie GiffordEditor and Contributing AuthorCopyright 2013 International Society of Automation67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved.Printed in the United States of America.10 9 8 7 6 5 4 3 2 1ISBN: 97

2、8-1-937560-67-6No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.Notice:The information presented in this publication is

3、 for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound profes-

4、sional judgment in using any of the information presented in a particular application. Additionally, neither the author nor the publisher has investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is res

5、ponsible for reviewing any possible patents that may affect any particular use of the information presented.Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or tradenames refe

6、renced belong to the respective owner of the mark or name. Neither the author nor the publisher makes any representation regarding the availabil-ity of any referenced commercial product at any time. The manufacturers instructions on use of any commercial product must be followed at all times, even i

7、f in conflict with the information in this publication.Library of Congress Cataloging-in-Publication in process.iiiTABLE OF CONTENTSPreface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vAbout t

8、he Editor and Contributing Author: Charlie Gifford. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiBook 3.0: Authors, Contributing Editors, and Reviewers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiiiChapter 1 APPLYING GLOBAL MOM SYSTEMS IN A MANUFACTURING 2.0 APPRO

9、ACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Why MOM and Not MES? . . . . . . . . . .

10、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Why Service-oriented Architecture (SOA) in Manufacturing? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6What is a standards-based integration vision? . . . . . . . . . . . . . . . . . . .

11、. . . . . . . . . . . . . . . . . . . . . . . 6Why MDM for Manufacturing? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Is EMI Best Positioned against or with Business Intelligence (BI)?. . . . . . . . . . . . . . . . . . . . . . . . .

12、15Evolution of Integration Approaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Bibli

13、ography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Chapter 2 THE ROLE OF SEMANTIC MODELS IN SMARTER INDUSTRIAL OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14、 . . . . . . . . . . . . . .25Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26The Manufacturing Complexity Problem? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15、 . . . . . . . 30Why Semantic Models? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Evolution toward Semantic Model-based Operations Integration . . . . . . . . . . . . . . . . . . . . . . . . . 38The Information Model The

16、 Heart of the Semantic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Semantic Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Conclusion . . . . . . . . . . . . . . . . . . . . . . . .

17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Chapter 3 APPLYING MANUFACTURING OPERATIONS MOD

18、ELS IN A DISCRETE HYBRID MANUFACTURING ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . 65Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66The Manufacturing Operations Domain . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Enterprise Domain (Architecture) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Defining Manufacturing Operations (Defining a MES/MOM System) . . . . . . . .

20、. . . . . . . . . . . . . 76Shop Floor Operations View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Shop Floor Systems: Organizational View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21、92Shop Floor Data Exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

22、1Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Chapter 4 DEFINING AN OPERATIONS SYSTEMS ARCHITECTURE. . . . . . . . . . . . . . . 103Introduction . . . . . . . . . . . . . . . . . . . . . . .

23、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104What is Operations Systems Architecture (OSA)?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Determine the Scope of the OSA . . . . . . . . . . . . . . . . . . . . . . . .

24、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Derivations of an OSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Steps for Development of a Product-independent OSA . . . . . . . . . . . . . . . . . . . . .

25、. . . . . . . . . . . . 112BOOK 3.0: Table of ContentsivWhat Does an OSA Look Like?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115Realize the Manufacturing OSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26、 . . . . . . . . . . . . . .145Manage the Development of the OSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27、 . . . . . . .146Bibliography. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147Chapter 5 A WORKFLOW-DRIVEN APPROACH TO MANUFACTURING OPERATIONS MANAGEMENT (MOM). . . . . . . . . . . . . . . . . . . . . . . .1

28、49Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150Challenges to Working Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151Overco

29、me the Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156The Changing Role of MOM Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157Beyond Dashboards . . . . . . . .

30、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158Manufacturing Workflows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161Enterprise Manufacturing Workflow Example . . .

31、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186Chapter 6 SCHEDULING INTEGRATION USING AN ISA-95 APPLICATION IN A STEE

32、L PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188Introduction to Production/Operations Sch

33、eduling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .189Interfaces of Scheduling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194Application to a Steel Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34、. . . . . . . . . . . . . . . . . . . . . . . . . . . .199Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214Chapter 7 INTELLIGENT INTEGRATION INTERFACE: I3, A REAL WORLD APPLICATION OF ISA-95 . .

35、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216Persuading and Educating about MOM-based Solutions . . . . . . . .

36、 . . . . . . . . . . . . . . . . . . . . . . .218What is I3? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220Mapping I3to ISA-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37、 . . . . . . . . . . . . . . . . . . . . . . . .233Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235Glossary ACRONYMS AND ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38、. . . . . .237Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249vPREFACEHello Innovators of Intelligent Manufacturing Operations,If you have followed the work of the ISA-chartered ISA-95 Bes

39、t Prac-tices Working Group, you may have noticed that as chairman and founder of this working group I have derived the book title for each collection of Manufacturing Operations Management (MOM) method-ology white papers from a classic science fiction book title. The title aligned with the general t

40、heme of the paper collection. The first two books were:1. The Hitchhikers Guide to Manufacturing Operations Management: ISA-95 Best Practices Book 1.0, which was derived from The Hitch-hikers Guide to Galaxy2. When Worlds Collide in Manufacturing Operations: ISA-95 Best Prac-tices Book 2.0, which wa

41、s derived from When Worlds CollideThe paper collection in Book 3.0 is titled The MOM Chronicles, which is derived from the legendary work of The Martian Chronicles by Ray Bradbury. Our working group has dedicated the Book 3.0 collection to Ray Bradbury, who passed away on June 5, 2012. Ray Bradbury

42、was one major influence in my life as a teenager looking for a positive direc-tion and way to influence the world. Mr. Bradbury was the author of more than three dozen books, including the celebrated literary works of Fahrenheit 451, The Martian Chronicles, The Illustrated Man, Dandelion Wine, and S

43、omething Wicked This Way Comes, as well as hundreds of short stories. He has written for the theater, cinema, and TV, including the screenplay for John Hustons Moby Dick and the Emmy Awardwinning teleplay The Halloween Tree. Sixty-five of his stories were adapted for The Ray Bradbury Theater on tele

44、vision. He received the 2000 National Book Foundations Medal for Distinguished Contribu-tion to American Letters, the 2007 Pulitzer Prize Special Citation, and numerous other honors.In The Martian Chronicles, written during the 1940s, Bradbury as one of Americas preeminent storyteller tells how huma

45、ns conquered the planet of Mars in 1999 while fleeing from a troubled and eventually atomically devastated Earth. Then the humans themselves are con-quered on Mars. In this classic work of fiction, Bradbury exposes our human ambitions, weaknesses, and ignorance in a strange and breath-taking world w

46、here humans do not belong. The Martian Chronicles fol-lows a “future history” structure similar to the paper collection structure of Book 3.0. The short stories, complete in themselves, come together as episodes in a larger sequential narrative framework as do the Book 3.0 papers as chapters of the

47、book. The overall structure of The Martian Chronicles is presented in three parts that are punctuated by BOOK 3.0: Prefacevitwo major catastrophes: (1) the near-extinction of the Martians and (2) the parallel near-extinction of the human race on Mars after their extinction on Earth. Starting in the

48、far-flung future of 1999, humans colonize Mars for a new beginning but take their shortsighted behavior with them. Below I draw the parallel to Book 3.0 explanations of how corporate IT colonized the plant operations with their shortsighted methods.In a crucial story, “And the Moon be Still as Brigh

49、t”, the fourth explor-atory expedition reveals the Martians have all but perished in a plague caused by germs brought by the previous human expeditions. This unex-pected development sets the stage for the second act and set of stories (December 2001November 2005), in which humans from Earth colonize the deserted planet with the few surviving Martians to make Mars a sec-ond Earth. However, as war on Earth occurs, most of the human settlers pack up and return to Earth. A global nuclear war ensues, cutting off con-tact between Mars and Earth. The third act and set o