Enterprise PI Enabling an Integrated Manufacturing Landscape

Transcription

1 Enterprise PI Enabling an Integrated Manufacturing Landscape Barry Higgins Janssen Biologics Ireland Copyright 2011, OSIsoft LLC. All rights Reserved.

2 Agenda Background Enabling MES Introducing PI Asset Framework (PI AF) MES data interface using PI AF 2 Copyright 2011, OSIsoft LLC. All rights Reserved.

3 Agenda Background OSIsoft and J&J Enabling MES Introducing PI Asset Framework (PI AF) MES data interface using PI AF 3 Copyright 2011, OSIsoft LLC. All rights Reserved.

4 About Janssen 3 Main areas: Consumer Medical devices & diagnostics Prescription Products JSC API Supply Chain. Chemicals 6 sites Biologics 5 sites 4 Copyright 2011, OSIsoft LLC. All rights Reserved.

5 Agenda Background OSIsoft and J&J Enabling MES Introducing PI Asset Framework (PI AF) MES data interface using PI AF 5 Copyright 2011, OSIsoft LLC. All rights Reserved.

6 Systems Overview JSC API - PCS Landscape JSC API DCS Vendors JSC API PLC Vendors 19% 43% 38% DCS PLC BMS 29% 26% 45% Emerson Siemens 4% 5% 24% ABB 67% Siemens Rockwell GE Other Various BMS s Emerson DeltaV Siemens PCS7 GE Unicorn ABB 800xA Various PLC s/ Instruments 6 Copyright 2010, OSIsoft LLC. All rights Reserved.

7 Why do we need the OSIsoft PI System? Very disparate systems landscape ranging from distributed process control systems with inherent historian capability to stand-alone instruments with paper printouts Require capability to capture and aggregate data for visualisation, reporting & analysis OSI PI = System Independent Enterprise Data Presentation Layer Various BMS s Emerson DeltaV GE Unicorn Siemens PCS7 ABB 800xA Various PLC s/ Instruments BMS Building Management System PLC Programmable Logic ler 7 Copyright 2011, OSIsoft LLC. All rights Reserved.

8 Philosophy for OSIsoft PI System in J&J Pharma Get away from counting tags Collect all data (GMP & non-gmp) Process, Alarm & Events, Batch Events Deliver a consistent infrastructure globally no differentiation from Commercial to R&D Provide common visualisation (thick & thin clients) Consolidated data visualization for improved process monitoring and historical batch analysis Consolidated alarm reporting for building management, process control, laboratory equipment, utility systems, warehouse equipment Targeted compliant reporting (RtReports) Autoclaves, washers (non-mes related!) 8 Copyright 2011, OSIsoft LLC. All rights Reserved.

9 Systems Landscape Positioning S95 ERP Level 4 MES PIMS LES LIMS Level 3 ELN PCS CDS Level 2 CDS: Chromatography Data Software ELN: Electronic Laboratory Notebook ERP: Enterprise Resource Planning LES: Laboratory Execution System LIMS: Laboratory Information Management System MES: Manufacturing Execution System PCS: Process System PIMS: Production Information Management System Process Instruments Lab Instruments Level 1

10 Agenda Background OSIsoft and J&J Enabling MES Introducing PI Asset Framework (PI AF) MES data interface using PI AF 10 Copyright 2011, OSIsoft LLC. All rights Reserved.

11 Where does the PI System fit? Product definition Production capability Production schedule Production performance Production Resource Management Detailed Production Scheduling Production Tracking Production Dispatching Production Performance Analysis MES Product Definition Management Production Data Collection OSIsoft PI Production Execution Management Equipment and process specific production rules Operational commands Operational responses Equipment and process specific data Production level 1-2 functions 11 Copyright 2011, OSIsoft LLC. All rights Reserved.

12 Set values Synchronization Process data, Batch data, Alarm & Events Process data Alarm & Events Telegrams Actual values Doc ID File Enabling MES Global MES ERP Material Master Overall Inventory Overall Genealogy Master Batch Record Master Production Schedule Production Orders DMS SOP s / WI s Drawings Instructions Local CAPA LIMS Manual Sample IDs Master material data Overall inventory Material lot status Production orders PAS X Production order status Material consumptions Inventory update Production Resource Management Detailed Master Batch Records Production Plan Execution Electronic Batch Recording Weigh & Dispense Review by Exception Material Management in Production Real-time Information Management System Login verification UserID & PW Manual J&J Users (LDAP / AD) Training Management Process System(s) Building Automation System(s) IPC instruments Scales & Printers 12 Copyright 2010, OSIsoft LLC. All rights Reserved.

13 The New Trinity PAS X Commands & setpoints to Process System Process Data collected in the PI System The PI System data referenced in the PAS X EBR PAS X EBR batch execution data referenced in the PI System. PI System Process System(s) 13 Copyright 2010, OSIsoft LLC. All rights Reserved.

14 Background OSIsoft and J&J Enabling MES Introducing PI Asset Framework (PI AF) MES data interface using PI AF 14 Copyright 2010, OSIsoft LLC. All rights Reserved.

15 Operational Commands Synchronization Real-Time Data Infrastructure: A Key Enabler Level 4 S95 Model Business Planning & Logistics Plant Production scheduling, Operational Management, etc. Level 3 Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Production Tracking, etc. EWI Batch Context EWI Data Process Data / Events Other Data Assets ELEMENT ELEMENT ELEMENT Template Level 2 Real-Time Data Infrastructure Common Data Presentation Layer Process data, Building automation data, Alarm & Events Connectivity Hierarchy Role based Level 1 Batch Continuous Discrete Level 0 Collections of reusable Elements 15 Value now. Value over time. Copyright 2011, OSIsoft, LLC. All rights Reserved.

16 PI Asset Framework Data structured and organized by asset Spans multiple PI Systems Non Time PI PI Series Server Data Sources 21 Incorporates non time series data Vendor Specific s Generic s Honeywell ABB Delta-V Rockwell OPC PI AF 2.0 XML Modbus Asset-Equipment Time Series Time Series Data Centric Sources Data access Sources to the Data SNMP Honeywell SCM RDBMS MES ABB Delta-V Rockwell Other Honeywell ABB Delta-V Rockwell Other

17 Introducing PI Asset Framework What is PI Asset Framework? Process Object Models which represent the logical components in your process. Allows data from multiple PI servers to be combined in one common view. Allows the user access to non PI data sources, e.g. external databases. Allows process specialists to build process relative models without the need for extensive PI System knowledge. 17 Copyright 2011, OSIsoft LLC. All rights Reserved.

18 PI AF in Janssen Super Class concept. Class based templates built in conjunction with process and subject matter experts. Only process critical information grouped together in a logical model. Ensures that the entire organisation have a common taxonomy. PAS X \ PI AF Using Unit based templates allows us to build unit based MBR elements that can be applied on other sites. 18 Copyright 2011, OSIsoft LLC. All rights Reserved.

19 Background OSIsoft and J&J Enabling MES Introducing PI Asset Framework (PI AF) MES data interface using PI AF 19 Copyright 2011, OSIsoft LLC. All rights Reserved.

20 From PI AF to MES and back PI AF Element Templates Class based template. Unit Elements created from template. Upload from PI AF Class based PCS MBR elements Building blocks for MBR modellers MBR Generation Class based MBR EBR Execution Unit resolved at runtime. Data retrieved from PI AF Unit Element 20 Copyright 2011, OSIsoft LLC. All rights Reserved.

21 Acknowledgements: J&J: Terry Murphy Barry Lawlor OSIsoft: Todd Brown Marc Gallant Glenn Hummell Chris Nelson TQS: Tom Quilty Cathal Horgan Thank you Copyright 2010 OSIsoft, LLC. 777 Davis St., Suite 250 San Leandro, CA 94577

22 The New Trinity! PAS X Commands & setpoints to Process System Process Data collected in OSI PI OSI PI data referenced in the PAS X EBR OSI PI Process System(s) 22 Copyright 2011, OSIsoft LLC. All rights Reserved.

23 Challenges at Level 2: Variable System Landscape Level 4 Level 3 Business Planning & Logistics Out of S88 Scope Plant Production scheduling, Operational Management, etc. Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Production Tracking, etc. Typical Process System Landscape DCS PLC BMS Level 2 Level 1 Batch Continuous Discrete Typical PLC Vendors Vendor A Typical DCS Vendors Vendor F Vendor G Vendor B Vendor C Vendor C Vendor D Level 0 Vendor E 23 Value now. Value over time. Copyright 2011, OSIsoft, LLC. All rights Reserved.

24 Operational Commands Synchronization Real-Time Data Infrastructure: A Key Enabler S95 Model Level 4 Level 3 Business Planning & Logistics Plant Production scheduling, Operational Management, etc. Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Production Tracking, etc. TIMESERIES DATA SOURCES TIMESERIES DATA SOURCES TAG TAG Data reference ELEMENT ATTRIBUTE WITH UOM i.e. FlowRate l/h ATTRIBUTE WITH UOM EWI Batch Context EWI Data Real-Time Data Infrastructure Common Data Presentation Layer NON TIMESERIES DATA SOURCES ATTRIBUTE WITH UOM i.e. LastCalibration UOM Units of Measurement Level 2 Level 1 Batch Continuous Process data, Building automation data, Alarm & Events Discrete Asset/Equipment centric access to information Non Time Series Data Sources PI Server 1 PI Server 2 Asset RDBMS LIMS Level 0 24 Value now. Value over time. Copyright 2011, OSIsoft, LLC. All rights Reserved.

25 Operational Commands Synchronization Real-Time Data Infrastructure: A Key Enabler Level 4 S95 Model Level 3 Business Planning & Logistics Plant Production scheduling, Operational Management, etc. Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Production Tracking, etc. EWI Batch Context EWI Data Real-Time Data Infrastructure Common Data Presentation Layer Process System Landscape with PI DCS PLC BMS Level 2 Process data, Building automation data, Alarm & Events Level 1 Batch Continuous Discrete Vendor Specific s Honeywell ABB Delta-V PI Server 1 Rockwell OPC Generic s XML Modbus SNMP Time Series Data Sources Level 0 Honeywell ABB Delta-V Rockwell Other 25 Value now. Value over time. Copyright 2011, OSIsoft, LLC. All rights Reserved.

26 Operational Commands Synchronization Real-Time Data Infrastructure: A Key Enabler S95 Model S88 Model Level 4 Business Planning & Logistics Plant Production scheduling, Operational Management, etc. Recipes Recipe Procedure Level Recipe Unit Procedure Manufacturing Operations Management Dispatching Production, Detailed Production Scheduling, Production Tracking, etc. Level 2 EWI Batch Context EWI Data Real-Time Data Infrastructure Common Data Presentation Layer Process data, Building automation data, Alarm & Events Equip. Context, Batch Context Batch Data 2.3 Recipe Operation Phases / Sequences Recipe Phase Equipment Phase Level 1 Batch Continuous Discrete 2.2 Equipment Module 2.1 Module Level 0 26 Value now. Value over time. Copyright 2011, OSIsoft, LLC. All rights Reserved.