1. Introduction: The importance of ISA-95 and the need to understand it
1) Essential elements of industrial integration
Technological advancements and adaptation: Rapid advances in industrial automation and digital transformation are increasing the importance of efficient information management and systems integration. An understanding of the ISA-95 standard is essential to adapt to these changes and effectively integrate the latest technologies.
Increased efficiency and productivity: ISA-95 standardizes and optimizes each step of the manufacturing process, improving overall efficiency and productivity.
2) Support strategic decision-making
Understand the hierarchical structure: By understanding the hierarchical model of ISA-95, organizations can see how information flows and decisions interact at each stage of the manufacturing and production process.
Resource optimization: By understanding the function and importance of each layer, organizations can allocate and manage resources more effectively.
3) Compliance and standardization
Compliance with industry standards: In many industries, regulatory compliance is essential. Knowledge of the ISA-95 standard helps organizations meet these regulatory requirements.
Global standardization: ISA-95 is an internationally recognized standard, which is important for adopting consistent processes and operations around the world.
As such, an understanding of ISA-95 is key to addressing the many challenges facing organizations and gaining a competitive advantage in the modern industrial environment. Therefore, an in-depth understanding of the specific roles and functions of each layer is essential for all manufacturing and operations managers. Let's take a closer look at each layer of the ISA-95 model.
Level 0: Process
1) Overview.
Definition: Level 0 refers to the most basic stage of the manufacturing and production process, where raw materials are processed and transformed into the initial form of the product. This process involves the operation of machinery and equipment, environmental monitoring through sensors, and the direct involvement of workers.
Importance: Level 0 is the foundation of the production process and is the key step that enables the physical transformation of raw materials into products. Activities at this level are critical because they directly affect the quality and productivity of the final product.
2) Components
Machinery and equipment: Machines and equipment used in Level 0 include CNC machines, presses, conveyor belts, robotic arms, etc. They are essential for precisely machining raw materials and creating semi-finished products.
Sensors: A variety of sensors are used to efficiently manage the manufacturing process and maintain consistent product quality. These sensors detect environmental variables such as temperature, pressure, humidity, and vibration in real time to optimize process conditions and proactively prevent problems.
Human activity: Human operators are responsible for critical tasks such as operating machines, overseeing processes, and performing quality checks. Their experience and judgment play an important role in making unique decisions that machines cannot.
3) Examples of processes
Machining: Raw materials are mechanically changed in form or character through processing to create semi-finished or finished products. For example, metals are cut, shaped, and polished to transform them into automotive parts.
Assembly: In assembly, multiple semi-finished products or parts are combined to form a finished product. This step requires precision and is a critical process that determines the functionality of the product.
Quality inspection: All products are inspected for quality before they are shipped. During this process, defective products are weeded out and either reworked or scrapped. Quality inspection is essential to ensure product reliability and increase customer satisfaction.
Level 1: Instrumentation and manipulation
1) Overview.
Definition: Level 1 is the layer responsible for direct process control during manufacturing and consists of devices that monitor and manipulate the production process in real time through various sensors, actuators, gauges, and valves.
Why: This layer is central to accurate data collection and process control in the manufacturing process. Proper adjustments based on real-time data can significantly improve product quality and production efficiency, while also contributing to cost savings and increased system reliability.
2) Key components
Sensors: Level 1 sensors detect various environmental changes that occur during the process, such as temperature, pressure, humidity, and physical location. This data is used to pinpoint the state of the process and provide the basis for any necessary adjustments.
Actuators: Actuators perform mechanical actions based on data from sensors or commands from a centralized control system. For example, they are responsible for running a motor, moving a machine, etc.
Instruments and valves: These devices regulate the flow, pressure, etc. of fluids to ensure the reliability and efficiency of processes. Valves regulate the opening and closing of pipelines, while instruments are important for measuring process variables to detect anomalies.
3) Examples of tasks
Data acquisition: Collecting data from the process in real time, which is important for optimizing the process, improving efficiency, and preventing failures.
Sending control signals: Based on the collected measurement data, the control system analyzes it and sends control signals to the machine or equipment to make the necessary adjustments. This process enables precise control of the process and maximizes production quality.
Process adjustment: Based on process data and control signals, various elements of the production process are adjusted to improve the quality of the final product and the efficiency of the production process. This contributes to cost reduction and optimization of resource use.
Level 2: Process Control
1) Overview
Definition: The Level 2 layer of ISA 95 includes systems that supervise, monitor, and control the manufacturing process in real time. The primary purpose of this layer is the control and optimization of actual production operations, and it plays a key role in increasing the productivity and efficiency of the factory.
Importance: Level 2 provides advanced controls that optimize the entire production process based on data collected in Level 1. It plays an important role in improving the performance of the process, reducing costs, and maximizing output.
2) Key components
Distributed Control Systems (DCS): DCSs ensure process reliability and consistency by integrating and automating control commands. They enable centralized management of complex operations throughout the factory.
Human-Machine Interfaces (HMI): HMIs provide an interface for operators to interact directly with the system. It enables real-time monitoring of system status and adjustments as needed, helping operators make decisions and actions instantaneously.
Supervisory Control and Data Acquisition (SCADA) software: SCADA software enables the monitoring and control of facilities distributed over large areas. The system provides a variety of functions, including data collection, event logging, and alarm management, and is especially useful in large installations.
3) Key functions
Supervision and control: Level 2 systems utilize real-time data to continuously monitor processes and make adjustments on the fly as needed. This is essential to continuously maintain process stability and optimization.
Data collection and analysis: Operational data is collected and analyzed to evaluate the efficiency of the process and identify improvements. This data also provides an important basis for making long-term process improvements and strategic decisions.
Operator interaction: HMIs allow operators to monitor system performance in real time and react quickly to anomalies or potential problems. This plays an important role in improving process efficiency and safety.
Level 3: Operations Management
1) Overview.
Definition: Level 3 is the layer that manages the day-to-day operations of a factory or production line through systems such as manufacturing execution systems (MES). These systems coordinate the entire production activity and track the manufacturing process in real time.
Why it's important: This layer is responsible for making production more efficient and cost-effective, and it coordinates processes to match planned production goals. Quality control, inventory management, scheduling, and more enable optimization of resources and the creation of products that meet customer requirements.
2) Key Functions
Production Planning: This function plans the resources and process time required to produce a product. It maximizes production efficiency by planning in detail the quantity of raw materials required, the arrangement of machines and manpower, and the working time for each process step.
Schedule management: Based on the production plan, the actual production schedule is managed and adjusted as needed. This allows for flexibility to respond to unforeseen circumstances, minimizes delays in the production process, and increases overall productivity.
Quality control: Continuously monitor and control the quality of your products. Any issues found during this process are addressed through immediate remedial actions, and the quality of the final product is maintained to the prescribed standards.
3) Integration and communication
System integration: Level 3 systems are integrated with lower-level control systems such as levels 1 and 2 to increase the efficiency of manufacturing management. This integration ensures consistency of data and facilitates the management of the entire manufacturing process.
Information transfer: Communicate the necessary information to higher levels (e.g., management) and lower levels (e.g., control systems) as appropriate. This information includes production data, quality metrics, schedule changes, and more, enabling effective decision-making and operations across the organization.
Level 4: Corporate Planning
1) Overview.
Definition: Level 4 encompasses high-level management systems that focus on the overall management and strategic planning of the enterprise. This layer includes systems such as enterprise resource planning (ERP) systems, which provide integrated support for enterprise-wide resource management and decisions.
Why it matters: This layer plays a key role in determining the overall operational and strategic direction of an organization. The plans and decisions made at Level 4 directly impact the day-to-day work orders and management direction at Level 3, setting the foundation for the long-term success of the organization.
2) Key Functions
Business strategy: Set the long-term goals and business strategy of the company. It includes market research, competitive analysis, and visioning, and is important for defining the company's growth direction and new business opportunities. The business strategy is the basis for all the company's activities and decisions.
Resource management: Responsible for the efficient management of a company's resources, including human, financial, and physical resources. This includes setting budgets, staffing, managing funds, and ensuring that resources are optimized and used efficiently.
3) Roles and Influence
Decision and direction setting: Determines the overall direction of the enterprise and sets consistent instructions and policies across the organization. This ensures that all business units and departments work in harmony, and supports the achievement of corporate goals.
Analyze performance: Periodically analyze and evaluate the overall performance of the company. This process compares results achieved with expectations and makes necessary strategic adjustments based on performance. Performance analysis provides an important feedback mechanism for enhancing a company's competitiveness and sustainable growth.
Conclusion
The ISA-95 standard plays a pivotal role in addressing the complexities and challenges of the manufacturing environment through industrial automation and digital transformation. By systematically understanding and integrating each step of the manufacturing process, the standard helps organizations manage information more effectively and increase the efficiency and productivity of their overall operations. The tiered approach, from Level 0 to Level 4, enables organizations to optimize resources, formulate management strategies effectively, and maintain consistent quality and performance across the enterprise.
As a global industry standard, ISA-95 also plays an important role in international cooperation and competitive advantage. It enables organizations to ensure regulatory compliance and paves the way for agile responses to market changes. Therefore, a deep understanding and implementation of ISA-95 is essential for all manufacturing and operations managers, as it is key to ensuring the long-term success and sustainable competitiveness of their organizations.
Overall, companies that leverage the ISA-95 standard will have the ability to efficiently manage resources, optimize operations, and make strategic decisions in complex manufacturing environments. This provides the foundation to pursue stable growth and development even in uncertain economic and market environments.
Korean Version : https://blog.naver.com/capslave/223414478815
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