ISA-95 Overview

ISA-95, also known as ANSI/ISA-95, is an international standard developed by the International Society of Automation (ISA). It provides a framework for integrating enterprise-level systems with control systems in manufacturing. The standard aims to improve communication and interoperability between different systems in an organization, such as enterprise resource planning (ERP), manufacturing execution systems (MES), and control systems.

Key Components

ISA-95 is divided into several parts, each focusing on different aspects of integration:

1. 1. Part 1: Models and Terminology

      • • Introduces a common terminology for describing the various components of the manufacturing process, including:

          • • Manufacturing Operations: Processes involved in converting raw materials into finished goods.
          • • Information Systems: Systems that collect, analyze, and report data related to manufacturing.

1. 1. Part 2: Object Model Attributes

      • • Defines the attributes of key objects in the manufacturing environment, such as production schedules, work orders, and product definitions. It emphasizes the importance of consistency and clarity in data representation.

1. 1. Part 3: Activity Models of Manufacturing Operations Management

      • • Outlines the activities involved in managing manufacturing operations, including:

          • • Production planning
          • • Resource allocation
          • • Production execution

1. 1. Part 4: Objects and Attributes for Manufacturing Operations Management

      • • Provides detailed information on the objects and attributes required to manage manufacturing operations effectively.

1. 1. Part 5: Business to Manufacturing Signals

      • • Focuses on the communication between business systems (like ERP) and manufacturing systems (like MES) to ensure seamless data exchange and decision-making.

Benefits of ISA-95

• • Interoperability: Facilitates the integration of various systems, improving data exchange and reducing redundancy.

• • Standardization: Establishes a common language and framework, making it easier for different systems to work together.

• • Efficiency: Enhances operational efficiency by streamlining processes and reducing errors associated with manual data entry.

• • Scalability: Supports the scalability of manufacturing operations, allowing organizations to adapt to changing business needs.

ISA-95: Levels of Manufacturing Operations

ISA-95 outlines a hierarchical model that describes how information flows between various levels of manufacturing operations. The framework typically defines five levels, from the enterprise level down to the physical control level.

 

Level 0: Physical Process

• • Description: This level represents the actual physical equipment and processes in the manufacturing environment. It includes sensors, actuators, and machinery that perform the physical operations.

• • Key Components:

    • • Physical devices (e.g., motors, valves, sensors)
    • • Process control systems (e.g., PLCs)

Level 1: Sensing and Control

• • Description: This level involves the direct monitoring and control of the physical processes. It encompasses the real-time data acquisition and control operations.

• • Key Components:

    • • Control devices (e.g., PLCs, DCS)
    • • Data acquisition systems
    • • Basic control functions (e.g., feedback loops)

Level 2: Control Systems

• • Description: This level encompasses the systems that execute control strategies and manage the operation of Level 1 devices. It is responsible for ensuring that production processes are running optimally.

• • Key Components:

    • • Distributed Control Systems (DCS)
    • • Supervisory Control and Data Acquisition (SCADA) systems
    • • Advanced control algorithms and strategies

Level 3: Manufacturing Operations Management (MOM)

• • Description: This level focuses on managing and optimizing manufacturing operations. It includes production planning, scheduling, and resource management.

• • Key Components:

    • • Manufacturing Execution Systems (MES)
    • • Production scheduling systems
    • • Quality management systems

    • • Performance monitoring tools

Level 4: Business Planning and Logistics

• • Description: This level represents the enterprise's business functions that oversee overall production and resource management. It connects manufacturing operations with business objectives.

• • Key Components:

    • • Enterprise Resource Planning (ERP) systems
    • • Supply chain management
    • • Sales and operations planning

Summary of ISA-95 Levels:

Level	Description	Key Components
0	Physical Process	Sensors, actuators, machinery
1	Sensing and Control	PLCs, data acquisition systems
2	Control Systems	DCS, SCADA, advanced control algorithms
3	Manufacturing Operations Management (MOM)	MES, production scheduling systems, quality management
4	Business Planning and Logistics	ERP systems, supply chain management