​An Introduction to the ISA 95 Framework

In the ever-evolving landscape of industrial automation and manufacturing, effective integration between enterprise and control systems is crucial for streamlining operations and maximizing efficiency. Achieving seamless communication and information exchange between different levels of a manufacturing organization is no easy task, but that's where the ISA-95 framework comes into play.

​The ISA-95, also known as ANSI/ISA-95, has emerged as a widely accepted international standard for integrating enterprise and control systems in manufacturing environments. ISA-95 provides standard and consistent terminology, which makes it much easier for supplier and manufacturer communication and creates a foundation for consistent information and operations models. This framework also makes it much easier for the wide variety of technologies (hardware, software, networking, etc.) to work together. Lets take a closer look.

Five Levels of the ISA 95 Framework

 
The ISA-95 framework consists of five levels, each with distinct characteristics and functions. The lower levels are grounded in the physical realm, while the higher levels are predominantly digital or cloud-based.
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• Level 0 - Production Process: At the foundation of the framework, Level 0 represents the physical environment where manufacturing activities take place. It encompasses data originating from sensors and signals on the factory floor, facilities, fleet, or any other sources related to the manufacturing process. The data collected at this level is typically at a very detailed level, measured in extremely fast time increments, such as milliseconds or even microseconds.
• Level 1 - Sensing and Manipulation: Moving up the hierarchy, Level 1 involves the sensing and manipulation of assets within the manufacturing environment. Sensors play a crucial role in broadcasting information such as temperature, pressure, or cycle-count, while assets can be manipulated by actions like opening or closing valves or turning equipment on or off. Data from sensors is ingested in a matter of seconds, enabling real-time monitoring and control.
• Level 2 - Monitoring and Supervision: Level 2 focuses on monitoring and supervision, where assets and systems are closely observed and visualized through raw data streams. Automation control hardware, coupled with software like SCADA (Supervisory Control and Data Acquisition) and HMI (Human-Machine Interface), enables the manipulation and control of physical processes. Examples include managing HVAC systems, controlling pumps, and monitoring asset values. Actions at this level occur within minutes.
• Level 3 - Manufacturing Operations Management: Level 3 operates in the realm between the physical and digital worlds and involves a broad range of operations. This level handles tasks such as scheduling, workload balancing, and optimizing production processes, all aimed at achieving the manufacturing goals of an organization. Manufacturing Operations Management (MOM) systems like MES (Manufacturing Execution Systems) reside within Level 3. CMMS (Computerized Maintenance Management Systems) span Levels 3 and 4, bridging the gap between operations and maintenance.
• Level 4 - Business Planning and Logistics: At the highest level within the ISA-95 framework, Level 4 focuses on aligning business goals with manufacturing operations. It encompasses high-level business and logistical planning, often measured in weeks or months. Enterprise Resource Planning (ERP), Supply Chain Management (SCM), and CMMS systems are situated in Level 4. Data from Level 3 plays a crucial role in facilitating informed decision-making for strategic planning and logistical activities.

The ISA-95 framework's multi-level structure allows organizations to effectively integrate their manufacturing operations with enterprise systems, enabling seamless data exchange and informed decision-making across different functional areas.

Parts of the ISA Framework

The ISA-95 standard is divided into eight parts as follows:
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• ISA-95 Part 1: Models and Terminology The initial part of the ISA-95 standard provides an overview of the models and levels of abstraction necessary for comprehending and mapping manufacturing operations and integrating them with business systems. It defines domain-level definitions, including control systems and enterprise systems, and outlines the functions, information flow, categories of information, and their definitions within each domain. Part 1 focuses on the integration between Levels 3 and 4 of the automation pyramid, detailing operations at the enterprise and manufacturing levels and highlighting the "Enterprise->Site->Area->Line" production model. It emphasizes the importance of understanding this part for system architecture and lays the groundwork for capturing data related to Overall Equipment Effectiveness (OEE) through an object model.
• ISA-95 Part 2: Object Model Attributes Part 2 of ISA-95 delves into specific topics related to modeling and provides standardized definitions and terminology for clear communication across different elements of a business. It focuses on the interface between manufacturing business hierarchy levels 3 and 4, discussing production capability, process segments, personnel and equipment models, materials, production scheduling and performance, and production routing and material dependencies. Part 2 describes the various attributes associated with these models, offering examples and linking strategies to gain a comprehensive understanding of the operation from a data perspective.
• ISA-95 Part 3: Activity Models of Manufacturing Operations Management In Part 3, ISA-95 helps define and standardize business processes, such as production, quality control, maintenance, inventory management, reporting and data collection, scheduling and performance analysis, and maintenance. This part enables the creation of a standard set of operational activities that integrate with the object model and describes how work is done within the hierarchy of the business. It facilitates enhanced integration between systems, promotes effective communication across the organization, and improves understanding of manufacturing operations, leading to increased operational efficiency, cost reduction, and enhanced competitiveness.
• ISA-95 Part 4: Objects and Attributes for Manufacturing Operations Management Integration Building on Part 3, Part 4 focuses on the integration and utilization of object and activity models with other systems. It provides guidelines for improving communication within the organization, defining data exchange between systems, and enhancing operational efficiency. Part 4 aims to reduce the time and cost required to reach optimal production levels, enabling vendors to supply appropriate tools for integration, helping stakeholders determine their needs, optimizing the supply chain, and reducing overall engineering lifecycle costs.
• ISA-95 Part 5: Business-to-Manufacturing Transactions Part 5 of ISA-95 establishes the structure, content, and format of information exchanged between manufacturing operations management systems and other enterprise systems. It leverages the models from Parts 2 and 4 to define data integration, facilitating standardized data exchange and clear communication between systems. Part 5 streamlines integration requirements and enables the use of standard protocols and approaches, promoting decoupling of vendor-specific implementations.
• ISA-95 Part 6: Messaging Service Model Part 6 focuses on the Messaging Service Model (MSM), which specifies how data is transformed when communicating between disparate systems. While it has been partially superseded by technological advancements like MQTT and Sparkplug B, Part 6 provides valuable concepts and best practices for translating data between local and global scopes. It emphasizes the importance of defining object and activity models and the data translation processes between systems.
• ISA-95 Part 7: Alias Service Model Part 7 expands on the data exchange between systems discussed in Part 6, emphasizing the conversion of local names to global names when integrating different systems. With the increasing number of potential integrations in a manufacturing organization, Part 7's detailed naming conventions become more significant. It outlines the importance of converting data between global and local namespaces for effective integration and offers insights derived from the concepts outlined in ISA-95.
• ISA-95 Part 8: Information Exchange Profiles Part 8 defines a framework for standardized information exchange profiles that facilitate integrations conforming to the ISA-95 approach. It primarily targets software vendors developing software with ISA-95 integrations. Part 8 enables the exchange of data in an "ISA-95 way" between software packages, supporting an agreed-upon format and allowing efficient communication. While the implementation of Information Exchange Profiles varies among software companies, ensuring consistent naming conventions across systems, as discussed in Parts 6 and 7, remains crucial. However, given technological advancements, Part 8 may be seen as less relevant in 2023, as newer approaches such as a Unified Namespace and MQTT offer efficient alternatives for integration.​  

Benefits & Challenges

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The ISA-95 framework offers several benefits for organizations looking to integrate enterprise and control systems in their manufacturing operations. However, like any implementation, it also poses certain challenges. Let's explore both the benefits and challenges of the ISA-95 framework:

Benefits of the ISA-95 Framework:

• Streamlined Integration: The ISA-95 framework provides a standardized model and guidelines for integrating enterprise and control systems. It ensures smooth communication and information exchange between different levels of the manufacturing organization, leading to improved collaboration, streamlined operations, and reduced integration effort.
• Operational Efficiency: By implementing the ISA-95 framework, organizations can achieve enhanced operational efficiency. The seamless flow of information across levels enables faster decision-making, optimized resource allocation, improved production planning, and increased overall productivity.
• Improved Visibility: The framework offers a structured approach to data exchange and information flow. This enhanced visibility into manufacturing operations allows organizations to gain insights into real-time process parameters, equipment status, quality control, and inventory levels. The improved visibility helps in identifying bottlenecks, detecting inefficiencies, and making data-driven decisions to improve performance.
• Scalability and Interoperability: The ISA-95 standard promotes standardization, modularization, and reusability. This allows organizations to scale their manufacturing systems and easily integrate new components or technologies. The framework also facilitates interoperability between different systems and vendors, enabling organizations to leverage the best-in-class solutions while maintaining compatibility.
• Continuous Improvement: With its focus on continuous improvement, the ISA-95 framework encourages organizations to evolve and optimize their manufacturing systems over time. By embracing standardized practices and staying up-to-date with emerging technologies, businesses can adapt to changing market demands, address evolving customer needs, and stay competitive.

Challenges of the ISA-95 Framework:

• Implementation Complexity: Implementing the ISA-95 framework can be a complex undertaking, especially for organizations with existing legacy systems. It requires aligning the existing systems and processes with the framework's guidelines, which may involve significant effort, system modifications, and training for personnel.
• Organizational Resistance: Introducing a new framework like ISA-95 may face resistance within the organization, particularly from stakeholders who are comfortable with existing systems and processes. Overcoming resistance and ensuring buy-in from key stakeholders is crucial for successful implementation.
• Integration Costs: Integrating enterprise and control systems according to the ISA-95 framework may involve investments in new technologies, software licenses, and infrastructure upgrades. These costs should be carefully evaluated and justified against the expected benefits and long-term ROI.
• Legacy System Compatibility: Organizations with legacy systems may encounter challenges in achieving full compatibility with the ISA-95 framework. Retrofitting or integrating legacy systems to conform to the standard may require additional development efforts or the use of intermediaries for data translation and communication.
• Skill and Knowledge Gap: Implementing the ISA-95 framework requires personnel with a deep understanding of the framework's principles, as well as expertise in system integration, data modeling, and interoperability. Organizations may need to invest in training or seek external expertise to bridge any skill gaps.

While the ISA-95 framework offers significant benefits, it is essential to consider the challenges that may arise during its implementation. By recognizing these challenges and addressing them proactively, organizations can maximize the benefits and successfully leverage the framework to enhance their manufacturing operations.

Conclusion

The ISA-95 framework serves as a vital tool for organizations seeking to optimize their manufacturing operations by integrating enterprise and control systems. By embracing the standardized model provided by the ISA-95, businesses can achieve seamless communication and information exchange between different levels of their manufacturing enterprise. From its hierarchical model to information exchange categories, functional and information models, and integration best practices, the framework offers a structured approach to enhance efficiency and decision-making.

Implementing the ISA-95 framework enables organizations to break down silos between the shop floor and broader business functions, facilitating improved collaboration, streamlined operations, and enhanced visibility. By adhering to the framework's guidelines and best practices, businesses can unlock the potential for continuous improvement, scalability, and adaptability, empowering them to thrive in today's dynamic manufacturing landscape.

In an era of increasing digital transformation, leveraging the ISA-95 framework empowers organizations to bridge the gap between their operational and strategic systems. By embracing this integration standard, manufacturing enterprises can unlock new opportunities, improve operational excellence, and ultimately stay competitive in an ever-changing global market.

By understanding the core principles of the ISA-95 framework and its application in real-world scenarios, organizations can embark on a journey towards achieving manufacturing efficiency and harnessing the full potential of their operations. The ISA-95 framework stands as a valuable resource for businesses aspiring to build a solid foundation for collaboration, information exchange, and optimized performance in the modern manufacturing ecosystem.​​