PERA Master Planning Appendices - PERA Enterprise Integration

194 Pages·2001·0.58 MB·English

A HANDBOOK ON MASTER PLANNING AND IMPLEMENTATION

FOR ENTERPRISE INTEGRATION PROGRAMS

APPENDICES

Edited by

Theodore J. Williams
Gary A. Rathwell
Hong Li

June 1996

(Current Edition February 2001)

Institute for Interdisciplinary Engineering Studies
Purdue University
West Lafayette, Indiana 47907
TABLE OF CONTENTS

APPENDIX I - GENERIC LIST OF MACRO-FUNCTIONS.....................................3
GENERIC TASKS OF A PLANT-WIDE SCHEDULING AND CONTROL HIERARCHY..............24
SUMMARY OF DUTIES AND TASKS FOR EACH OF THE LEVELS OF THE HIERARCHY........39
THE DATA FLOW GRAPH – A FUNCTIONAL NETWORK VIEW OF THE CIM REFERENCE
MODEL...........................................................................................................................53
SOME FURTHER EXAMPLES............................................................................................91
APPENDIX II – EXAMPLES OF THE POTENTIAL BENEFITS OF
ENTERPRISE INTEGRATION...................................................................................97
INVESTMENT JUSTIFICATION..........................................................................................97
APPENDIX III – EXAMPLE MISSION, VISION & VALUES, OBJECTIVES,
STRATEGIES, GOALS, & CSFS...............................................................................109
EXAMPLE MISSION, VISION AND VALUES....................................................................109
EXAMPLE OBJECTIVES, STRATEGIES AND GOALS........................................................109
EXAMPLE BUSINESS STRATEGIES ................................................................................110
EXAMPLE BUSINESS PLAN...........................................................................................111
EXAMPLE CRITICAL SUCCESS FACTORS.......................................................................111
APPENDIX IV - ENTERPRISE INTEGRATION PLANNING TEAM................130
INTRODUCTION............................................................................................................130
ESTABLISHING THE ENTERPRISE INTEGRATION PLANNING TEAM BASIS......................130
APPENDIX V - GLOSSARY.......................................................................................146
Appendix I - Generic List of Macro-Functions

As emphasized in Chapter 1, the overall applicability of the Purdue Enterprise Reference
Architecture depends to a great extent on the development of a set of generic tasks, functions and
macro functions to describe an enterprise integration system or indeed any enterprise.

The Purdue Reference Model for CIM [81] developed two such lists, one based on the Scheduling
and Control Hierarchy View and another based on the Data Flow Diagram View of the Reference
Model. It then proceeded to show the correlation of these two apparently widely different lists by
cross-referencing the task titles used and their point of application in each view. For the sake of
completeness of this Guide, that material will be reproduced here, along with considerable related
material on the architecture.

This appendix will show the correlation between the Purdue Enterprise Reference Architecture
and the Vendor Reference Model for CIM.

Scheduling and Control Hierarchy Diagram

The Scheduling and Control Hierarchy View from the Reference Model [81] as mentioned above
is shown in Figure AI-1. It is a Type 1 architecture developed to categorize the tasks carried out
by the industrial control system for a complete plant or company. Figure AI-2 shows that this
same diagram with modifications only for the names of the functions involved will characterize
the control tasks of either a continuous or discrete manufacturing industry plant. Figure AI-3
expands the earlier diagrams to cover a company with multiple plants.

This diagram correlates to the Purdue Enterprise Reference Architecture as noted in Chapter 1 in
that:
1. All functions and operations on the left-hand (manufacturing) side of the
Purdue Reference Architecture Diagram can be represented as relating only
to Level 0 of the Purdue Scheduling and Control Hierarchy view of the CIM
Reference Model [81].
2. Conversely all functions and operations shown on the right-hand
(information) side of the Purdue Reference Architectural Diagram relate only
to Level 1 and higher of the Purdue Scheduling and Control Hierarchy view.

Functional Block Diagram

Another example of these architectural views is the functional block diagram of Figure AI-4. It
will be used along with the hierarchy diagram in the discussion to follow as another way to
indicate the relationship of the several sub-architectures to each other.

Management and staff functions as defined here include all the usual functions such as finance,
procurement, etc. Research and development and sales are shown on each side of marketing
since marketing often serves as an interface between these two functions. Manufacturing as
APPENDIX I – Generic Macro-Functions
defined here includes all of its subsidiary functions such as maintenance and its management,
shipping, waste treatment, etc.

Note: It was just mentioned above that the Factory Scheduling and Control System block of
Figure A1-4 represents Levels 1 to 4A of Figure A1-1 and A1-2 of the Purdue Scheduling and
Control Hierarchy and the Manufacturing System block represents Level 0 of the hierarchy
presented there. Also the remainder of the diagram (Management and Staff Functions, Sales,
Marketing, Research and Development, and Engineering) represents those personnel not directly
involved in the day-to-day operations of the manufacturing plant, i.e. Level 4 of Figure A1-1 and
A1-2 and Level 5B of Figure A1-3.

A few words are appropriate on the definitions of the staff functions represented on Figure AI-4.
Engineering is represented in terms of its two major functions, those related to products on the
one hand (Product Design and Process Planning) and facilities on the other (Facilities Design and
Process and Facilities Improvement). These two functions operate on two different time scales
(because of the differing nature of their missions). Process Engineering prepares process plans
for the production of desired products as these plans are needed by manufacturing or when new or
revised products are developed by the Product Design function. Likewise Facilities Engineering
is responsible for the engineering of facilities maintenance as needed by Manufacturing and for
the design of new or modified manufacturing facilities.

Marketing's task is the determination of the Customers' needs for the product or service which the
Enterprise offers at present or should offer in the future. These involve determining what, where
and in what quantity. Also involved are cost/quality tradeoffs and delivery capabilities.

The Sales organization makes the services of the Enterprise available to the Customer through
customer contacts, advertising, collection of orders and negotiation of sales contracts. Research
and Development converts Marketing requests into proposed new or improved products or
services of the Enterprise and works through Engineering to convert these to viable designs and
process plans for their production.

Figures AI-5 and AI-6 describe the relationship of the Information Architecture and the
Manufacturing Architecture to each other. The reader should review Figures AI-8 through AI-11
versus Figures AI-12 through AI-18 for the corresponding cases in the structural diagram of the
Purdue Enterprise Reference Architecture. Note that these diagrams can represent either the
definition (functional) or the specification (implementation) case. Figures AI-7, AI-8 and AI-9
show the idealized relationships of the Information Systems, Manufacturing Equipment and
Human and Organizational Architectures to each other. In contrast to Figures AI-5 and AI-6
these represent only the implemented case. These do not coincide with the corresponding
divisions of the functional networks in the definition phase of the Architecture as do Figures AI-5
and AI-6 because of the assignment of tasks from both of these areas to the Human and
Organizational Architecture as described in Chapter 1. Figures AI-10 and AI-11 show the
division of the Human and Organizational Architecture with its functions assigned to either the
Information Architecture or the Manufacturing Architecture of Figures AI-7 and AI-8.
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APPENDIX I – Generic Macro-Functions

Relationship of PERA Block Diagram and Structural Forms
Figures AI-12 to AI-18 further classify the block diagram form of the Architecture by comparing
the figures just presented to corresponding ones showing the structural form of the PERA
Architecture. Despite their simplistic form, the figures are included to prevent any
misunderstanding of the meaning of the block diagram form of the Architecture and its
correspondence to the structural form. The block diagram form has several important uses as will
be seen in the remainder of this text. It must be mentioned early that the lists of functions to be
discussed here represent only the tasks included in the Scheduling and Control block of the
architecture as represented in the Factory Scheduling and Control block of Figure AI-4. The
other blocks of the Information Architecture as shown on that figure are not yet listed in terms of
the tasks involved. Such a list for the Manufacturing Architecture would be much more difficult
to prepare because of the relative lack of generality in manufacturing systems compared to
scheduling and control functions.

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APPENDIX I – Generic Macro-Functions

LEVEL 4B
S
R
E
MANAGEMENT PLANT D
R
DATA MANAGEMENT O
PRESENTATION INFORMATION SE
L
A
S
(LEVEL 4)
Y PLANT LEVEL 4A S
H LEVEL N
OL HIERARC OPESPRURAPOTEDIROUVCNISTAIILOO NNAND PSLACOMNHPATEEN DPRAURGALOTEINIDMOGUENC NAATTNLIODN OITACIINUMMOCREHTO HTIWSAERA
R
T
N
NG AND CO (LLEAEVRVEEELAL 3) SUCPOERNVSIOSLOER'S COCRODINOITNRRADATII-NOAARNTE I(OASHNO)P MMUNICATIONSWITH OTHERUPERVISORYSYSTEMS
LI O S
U C
D
E S
H N
SC (LLEUEVNVEIETLL 2) SUCPOERNVSIOSLOER'S WORNKCU OCMNEETLRLRI OC (DLA)LIRECT MMUNICATIOWITH OTHERCONTROLSYSTEMS
O
C
WORK STATION
OPERATOR'S
(COMPUTERIZED
CONSOLE
NUMERICAL CONTROL
(LEVEL 1)
DEDICATED PROGRAMMABLE
LOGIC CONTROLLERS
S
N
LR O
(LEVEL 0) PROCESS ALL PHYSICACHEMICAL OSPATIALANSFORMATI
R
T
FIGURE AI-1 ASSUMED HIERARCHICAL COMPUTER CONTROL STRUCTURE
FOR A LARGE MANACTURING COMPLEX (Computer Integrated Manufacturing
system –CIM )

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APPENDIX I – Generic Macro-Functions

LEVEL 4B
S
HY PMRAENSADEGANETTAMA TEINOTN MINAFRNOEARFGIMNEAEMTREIYON NT S ORDER
C E
R AL
A S
R
E (LEVEL 4)
CONTROL HI PLELAVNETL LEVELO 4PAESP RURAPOTEDIROUVNCIASTLIIOO NNA ND SCMOHAP RENEDERAUFGAILNTEINIEMOGRNEY NAA LNT D NIICATIONS TH OTHER AREAS
D MUWI
N M
A O
G C
SCHEDULIN (LELAVEREVELEA L3 ) SUCPOERNVSIOSLOER 'S CPOROOCREDSINSA UTINOINT OMMUNICATIONS WITH OTHER SUPERVISORY SYSTEMS
C
S
(LLEUEVNVEIETLL 2 ) SUCPOERNVSIOSLOER 'S SUCPOERNVTRISOOLR Y MMUNICATION WITH OTHER CONTROL SYSTEMS
O
C

DISTRIBUTED
OPERATOR'S
DIGITAL
CONSOLE
CONTROLLERS

(LEVEL 1)

SPECIALIZED DEDICATED

DIGITAL CONTROLLERS
S
(LEVEL 0) CONTINUOUS PROCESS (e.g. REFINING) ALL PHYSICAL CHEMICAL OR SPATIALANSFORMATION
R
T
FIGURE AI-2 ASSUMED HIERARCHICAL COMPUTER CONTROL STRUCTURE
FOR A CONTINUOUS PROCESS PLANT (such as Petrochemicals)

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APPENDIX I – Generic Macro-Functions

LEVEL P5MBRACENOSADEMGANPTETAAMAN TEYION TN MINACFNOOARMGMPEAAMTNEIYON NT ES ORDERS
L
A
S
(LEVEL 5)
COMPANY LEVEL 5A
LEVEL COMPSASAUSCNPSHYEIEG PRDNRVUMOILSEDIINONUGTNC TION PSAR SCCSOHOIEDGMDUNPUCMALTENIINONYGN T MUNIICATIO H OTHER PLANTS
HY COMWIT
C
R
TROL HIERA (LPLEELVAVENELTL 4 ) OPSPEURRPOAETDRIUOVCNITSAIILOO NANN D PSLACMONHPATEEN DPRAURAGOLTEIIDNOMUGNEC ANATLTNI O DN OMMUNICATION WITH OTHER AREAS
N C
O
ULING AND C (LLEAEVRVEEELAL 3 ) SUCPOENRSVOISLOER 'S CINOTRRDAIN-AARTEIOAN MMUNICATIONS WITH OTHER SUPERVISORY SYSTEMS
ED CO
H
SC (LLEUEVNVEIETLL 2 ) SUCPOERNVSIOSLOER 'S WORK NCCUEOMLNLET RR(DIOCIRLA)EL C T MUNICATIONS OTHERWITH CONTROL SYSTEMS
M
O
C
OPERATOR'S WORK STATION
CONSOLE (COMPUTERIZED
NUMERICAL CONTROL
(LEVEL 1)
DEDICATED PROGRAMMABLE
LOGIC CONTROLLERS
S
L, R ON
(LEVEL 0) PROCESS ALL PHYSICACHEMICAL OSPATIAL ANSFORMATI
R
T
FIGURE AI-3 ASSUMED HIERARCHICAL COMPUTER CONTROL STRUCTURE FOR
AN INDUSTRIAL COMPANY (MULTI-PLANT) TO SHOW LEVEL 5 AND ITS
RELATIONSHIP TO THE REVISED LEVEL 4

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APPENDIX I – Generic Macro-Functions

RESEARCH
MANAGEMENT AND
AND MARKETING SALES
STAFF FUNCTIONS
DEVELOPMENT
ENGINEERING
PRODUCT PROCESS
FACTORY
DESIGN PLANNING
SCHEDULING
AND CONTROL
PROCESS & SYSTEM
FACILITIES
FACILITIES
DESIGN
IMPROVEMENT
MANUFACTURING
SYSTEM
FIGURE AI-4 BLOCK DIAGRAM OF AN OVERALL ENTERPRISE INTEGRATION SYSTEM
(FOR REPRESENTING THE VARIOUS ARCHITECTURES DESCRIBED HEREIN)

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APPENDIX I – Generic Macro-Functions

INFORMATION ARCHITECTURE
RESEARCH
MANAGEMENT AND
AND MARKETING SALES
STAFF FUNCTIONS
DEVELOPMENT
ENGINEERING
PRODUCT PROCESS
FACTORY
DESIGN PLANNING
SCHEDULING
AND CONTROL
PROCESS & SYSTEM
FACILITIES
FACILITIES
DESIGN
IMPROVEMENT
MANUFACTURING
SYSTEM
FIGURE AI-5 THE INFORMATION ARCHITECTURE ALSO FUNCTIONALLY
REPRESENTS THE INFORMATION FUNCTIONAL NETWORK

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