by Gary Mintchell | May 30, 2010 | Automation, Events, Software
MESA announces the publishing of MESA White Paper #28: “Lifecycle of Service Creation using the ISA-95 MOM.” The white paper details the lifecycle of Manufacturing Operations Management (MOM) Service creation using the ISA 95 MOM standard for services oriented architectures (SOA) for manufacturing. It discusses the process of decomposing the ISA 95 Part 3 core functions from the global and strategic levels of the manufacturing enterprise to the atomic level of the plant’s manufacturing operations. The outcome of this process is 1) the MOM atomic functions are mapped to manufacturing reusable Services across different manufacturing types or forms and 2) an MOM Functional Services Gap Analysis is applied to identify manufacturing automation and operations gaps.
This paper was produced as part of the MESA/ISA 95 Best Practices Working Group through an international peer review process involving 5 or more subject matter reviewers. This MESA White Paper will also be published in one of two methodology best practices collection, Book 2.0, The MOM Chronicles, or Book 3.0, When Worlds Collide in Manufacturing Operations (Collections published by ISA, 10/1/10).
This white paper is available here. All of MESA’s white papers are available for $25.00 per paper for individual papers, or become a MESA premium member and have complimentary access to over 250 white papers, presentations, MOM/MES guidebooks, industry studies and web casts.
The content of this paper is part of an open discussion in the below UnConference Session at MESA 2010 North American Conference held June 21-23 in Dearborn, Michigan. Register here for the Conference.
The Unconference session is “Beyond Standards–Unlocking Your Operations Potential” held on Wednesday, June 23, 2010, 9:00am-12:00pm.
Potential specific topics include the following with final conversations determined by the participants’ requests:
- ISA-95 Maturity Model Assessment and Migration Strategies
- Architectures for manufacturing operations master data. And, who and how should it be governed?
- Applying SOA to manufacturing operations architectures
- B2MML Integration Patterns and Data Mapping
- Integration PLM, ERP and MOM in a Discrete Manufacturing Environment
- Integration of Manufacturing Intelligence with MOM
- ISA-95 Contextualized Operations Workflows for Industrial BPM
Facilitated by:
Charlie Gifford
Chair, ISA-95/MESA Best Practice Working Group
Chair, MES/MOM Ask the Expert Committee for Managing Automation Magazine
Chief Manufacturing Consultant, 21st Century Manufacturing Solutions LLC
Dr. Thomasma / Capgemini Americas / Detroit
Projects & Consulting
Michael Grasley, P.Eng.
Director, MES Consulting
ASECO Integrated Systems
by Gary Mintchell | May 29, 2010 | Operations Management
Other than journalists rushing to judgement and politicians rushing to posture for voters, another group that rushes to the front for publicity is PR gurus. You begin to see blog posts, news releases (that actually get picked up) or TV news bites from people pushing to get noticed by advising, in this case, what BP should do, or should have done, to spin the news of oil spill into something positive.
Rex Hammock has the right idea. BP’s brand image is toast for a long time in the U.S. Any spin just makes it worse–and reflects poorly on the PR profession. The only question is–when does BP change the name of its retail locations in the U.S. to Amoco?
by Gary Mintchell | May 28, 2010 | Marketing
So, who can best fix problems? Who would you send to stop the flow of oil in the Gulf–an engineer, bureaucrat or journalist? I’m sorry, journalists don’t fix things, they point fingers. So, what use are they in the middle of a crisis. They are like historians recording the facts (of the winners) after the event.
What’s bringing this on (realizing that for the past 12 years, I’ve been a journalist) was listening to one of those happy talk little interviews among the insiders pieces on “All Things Considered” on NPR. So they gather three political writers with no knowledge of much of anything other than how to write soundbites for radio telling engineers how to fill the hole in the sea bed. Or speculating that bureaucrats should have been making engineering decisions.
At this point, that is all wasted energy. When the immediate problem has been solved, we should find out things such as when regulators were bought off, or when a manager overroded an engineering decision because it would take too long, cost too much, and so on (all of us who have worked for a living have experienced these sorts of things).
How about doing something revolutionary–report on the facts? That’s what I’d like to hear.
by Gary Mintchell | May 27, 2010 | Automation, Operations Management, Organizations, Process Control
WBF took 2009 off when it looked like no one had travel budgets (except for harried magazine editors). This year’s conference held this week at the conference center at the University of Texas in Austin presented the overall best quality presentations I’ve ever seen (or heard). The shame of it was that attendance should have been much better. We’ll have to work on that for next year. We need the industry’s thought leader engineers and operations managers there–both to learn and to interact.
I cannot report in depth on all the papers. I’ll see if there’s a way you can purchase them or otherwise obtain them through WBF. As an aside–a couple of notes about the organization. It is organized around ISA88, known as the batch management standard. The original name was World Batch Forum. Trouble is much of ISA88 is applicable in many parts of continuous process. But engineers in continuous sniff at the word “batch.” Therefore, make the organization’s name more general. And, rather than rewrite the standard to include instances where it is applicable to continuous, a new committee has been formed to develop ISA106. More on that in a later post–and an invitation to help in the work of developing the standard. Speaking of ISA, the organization is also in the initial recovery stage after leaving an ill-fated relationship with that organization.
Here is the speaker list with a few comments. Just skimming the list shows the variety of topics. There was enough technical detail in each to whet the appetite of those working in that area to ask for deeper information.
Dr. Thomas Edgar, Professor in the Chemical Engineering Department at University of Texas. Energy Awareness gave the opening keynote. His talk centered on energy. Here are a few points he raised: Engineering departments need to increase energy IQ of engineering grads. There is no course taught, so few understand all the technology and issues, therefore, we get soundbite journalism. But no one would read a longer news piece anyway. The chem industry need to use renewables. There are many opportunities for engineers to contribute to energy technology. It’s a slow process, need to start now. Further, we need to develop a culture of personal responsibility vs. personal freedom for energy consumption in the US (used to have a culture of saving vs. culture of consumption).
Ed Brown, Project Leader, Avid Solutions, “Implementing Manufacturing Operations Management.” Big Bang is usual implementation design, swoop in and install complete suite of MOM applications. This forces culture change in the organization–“you must change the way you work.” It’s also expensive, running $250K for a plant and into $10 million or more for a corporation. Consider evolution to Big Bang: It has a reasonable capital investment. Develop capabilities that reflect business goals and objectives, pick the best for implementation.
Jorgen Beck, Automation Specialist, NNE Pharmaplan, “Fast & Reliable ISA88 Implementation of a Greenfield Facility.” Some benefits of thinking about your design based on using ISA88 as the model include: equipment is always in a well-defined state; phases are easy to design; different unit classes can use the same phases (as designed); and, you don’t have to think about common resources.
Wayne Gaafar, Sr. Batch Consultant, Honeywell, “Using ISA88 to Automate Procedures at Continuous Processing Facilities.” “Real knowledge is in the collective intelligence of the operators.” Continuous plants have elements of batch–just don’t call it that–that include sequence, phase, transition. Using ISA88 to define these helps document these pieces of the process, which is good since out-of-date documentation is still a problem. For example, if restructuring a distillation train startup, breaking it into ISA88 analysis will help the engineer find opportunites for improvement of startup time and other areas. You can make the process standard across the plant. You can capture intellectual property for standardizing and for reducing variability. The reason to capture this is not to get rid of operators through automation. “We never will get rid of operators, and we don’t want to.”
Jerry Sandoval, Consultant, GA Sandoval Consulting LLC, “How To Implement MES Without Making a MESS.” Much of implementing MOM has nothing to do with technology. Working with people and understanding processes is key.
Dennis Brandl, BR&L Consulting, “Manufacturing Science Model for Quality by Design and Risk Assessments.”
Mark Weinmann, Sr. Project Manager, Chevron, Eric Heavin, Application Engineer, Yokogawa of America, “A Well Oiled Interface–A Lubricants Manufacturer’s Slick B2MML Solution.” B2MML makes a reliable interface, changes are handled more easily, interface & message data “openness” allowed for re-use on other projects.
Dave Chappell, CTO, CMAa, “The Birth, Life and Death of an ISA88 Control Recipe” took a look at the life cycle of a recipe.
Niels Christian Andersen, Specialist, NNE Pharmaplan, “Electronic Document Management” described a project implementing electronic document management and showed the many benefits of going paperless.
Ragunathan Kanagavelu, Sr. Consultant, IBM, “Real Time Integration of Shop Floor Systems in Manufacturing Industries.”
Rober Wojewodka, Technology Manager, Lubrizol, Dawn Marruchella, Delta V Batch Product Marketing Manager, Emerson, “Benefits Achieved Using Online Analytics in a Batch Manufacturing Facility.” There is data everywhere, and it’s a heavy load. Talk about alarm management, but what about analyzing the process to prevent alarms in the first place. Use many stastical analyses–Dynamic Time Warping and other multivariate analyses, but then taking results back in single variables that operators and engineers can understand easily. Done in the MOM software.
Marcus Tennant, Principal Systems Architect, Yokogawa, “Modular Procedural Automation-Get Out of your Niche” looked at procedural automation as described in ISA88 and its applicablity in continuous process.
Chris Monchinski, Director, Automated Control Concepts, “ISA95 Enables Flexible Discrete Manufacturing.” ISA95 is the “Universal Translator.” Did a project. Convinced engineering that ISA95 was the way to go, but then had to go to IT. Took a little doing, but when you can gather engineering and IT around a table and each sees the benefits of moving data this way, it’s good for the company.
David Strobhar, Chief Human Factors Engineer, Beville Engineering, (and Center for Operator Performance), “Operator Performance as a Function of Alarm Rate and Interface Design.” Described research on operator interface and operator performance. Automation World provided an early look at that report in our May issue. With an additional podcast with Strobhar.
John Robert Parraga, Global Process Technical Consultant, Rockwell Automation, “Clean in Place Made Simple.”
Joseph Maguire, Lead Automation Engineer, Bristol-Myers Squibb, Christie Deitz, Sr. Principal Engineer, Emerson, “Electronic Workflow for a Bioreactor” described how to use electronic workflow in the development and execution of a project.
Patrick Kennedy, CEO and founder, OSIsoft, gave the second day keynote. His talk also focused on energy then moved to project management. One takeaway is this observation, “The new grid is really about bidirectional communication between electric ity generators and electricity consumers. The problems of solar and wind are that they are intermittent and require peaker generation for instantaneous smoothing of the supply, so power control in the larger scope is a dynamic control problem.”
