Integrating CMMS with ISA-95 for Smart Manufacturing

Integrating computerized maintenance management systems (CMMS) (opens in new tab) with the ISA-95 (also known as ANSI/ISA-95 and IEC 62264) standard presents new opportunities for enhancing efficiency, reliability, and intelligence. This integration is set to change the way maintenance management is handled and offers a new structured approach to connecting maintenance operations with broader manufacturing execution and enterprise systems. In this blog, we will explore the importance of ISA-95 in smart manufacturing and industry 4.0, the benefits of integrating CMMS with this standard, and some of the challenges that come with it.

What is ISA-95 and what is its connection with the Purdue model?

ISA-95, the International Society of Automation’s standard, for enterprise-control system integration, provides a framework for integrating enterprise and control systems. Its goal is to bridge the gap between the management and operational layers within manufacturing, facilitating seamless communication and data exchange.

The Purdue model, also known as the Purdue Enterprise Reference Architecture (PERA), is a hierarchical model that defines the interaction between different layers of manufacturing enterprise, from the physical process to business planning and logistics. The model is divided into five levels:

• Level 0: Physical process. The actual physical processes occurring on the manufacturing floor, such as chemical reactions or assembly operations.
• Level 1: Sensing and manipulation. Devices that monitor and manipulate physical processes, including sensors and actuators.
• Level 2: Control. Control systems like PLCs (Programmable Logic Controllers) (opens in new tab) and DCS (Distributed Control Systems) that manage the physical processes.
• Level 3: Manufacturing Operations Management (MOM). Systems that manage production workflows, track work-in-progress, and ensure quality control.
• Level 4: Business planning and logistics. Steps for business planning, inventory management, and logistics are typically managed by ERP (Enterprise Resource Planning) (opens in new tab) systems.

ISA-95 fits into the Purdue model by focusing on levels 3 (manufacturing operations management) and 4 (business planning and logistics). The alignment of ISA-95 and Purdue ensures that manufacturing processes are well-coordinated with business objectives, enhancing overall efficiency.

Example of ISA-95 working with the Purdue model

A manufacturing facility aims to improve equipment reliability through predictive maintenance in this scenario. ISA-95 facilitates the exchange of maintenance schedules and equipment health data between the CMMS in the ERP system at level 4 and the manufacturing execution system (MES) at level 3. Additionally, the supply chain management (SCM) data lives alongside the CMMS and ERP system at level 4. This integration enables predictive maintenance, triggering maintenance tasks based on real-time condition monitoring data, reducing downtime, and enhancing equipment reliability.

The significance of ISA-95 in Smart Manufacturing

Smart manufacturing leverages advanced technologies such as IioT, SCADA, artificial intelligence (AI), machine learning (ML), big data analytics, and automation to create highly efficient and flexible production systems. These technologies are often referred to as industry 4.0 technologies. For more context, industry 4.0. is known as the fourth industrial revolution, where automation and data exchange trends occurred in manufacturing.

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Now, ISA-95 standardizes how information is exchanged between different systems and layers in smart manufacturing. This standardization is essential for creating an interconnected manufacturing environment where data flows seamlessly, enabling real-time decision-making and process optimization. By adhering to ISA-95, manufacturers can ensure system interoperability, reduce integration costs, and improve scalability.

An example of ISA-95 in smart manufacturing would be in what’s considered a smart factory. A smart factory uses interconnected systems and devices to communicate seamlessly with one another. Imagine a factory floor, with every single asset connected to a core system, communicating real-time information. That’s the basic understanding of a smart factory. Smart factories also encompass industry 4.0 technologies.

One of ISA-95’s primary roles is to facilitate seamless data integration between enterprise systems (level 4) and manufacturing operations systems (level 3). By standardizing the data exchange protocols and interfaces, ISA-95 ensures that data from different sources can be easily combined and analyzed, providing a comprehensive view of the manufacturing process.

In a smart factory, production schedules generated by an ERP system are automatically communicated to the MES. The MES then coordinates the execution of these schedules on the shop floor, collecting real-time data from various sensors and devices. This data is fed back into the ERP system for analysis, enabling continuous optimization of production plans. ISA-95 ensures that all systems within a manufacturing organization work together, this enhances efficiency, reliability, and flexibility. As smart manufacturing continues to evolve, the role of ISA-95 will become increasingly important, driving the future of manufacturing innovation.

Benefits of integrating CMMS with ISA-95

Integrating CMMS with ISA-95 offers many benefits that contribute to the advancement of smart manufacturing. Here are some of the advantages:

1. Enhanced efficiency: ISA-95 provides a structured approach to synchronize maintenance schedules with production plans, minimizing downtime and ensuring that maintenance tasks are performed at the optimal time.
2. Improved reliability: A seamless connection between CMMS and ISA-95 enhances the reliability of manufacturing operations. Real-time data exchange allows for predictive maintenance, identifying and addressing potential issues before they lead to equipment failure. This proactive approach reduces unexpected breakdowns and extends the lifespan of machinery.
3. Intelligent decision-making: The integration facilitates the collection and analysis of comprehensive data from both maintenance and production systems. This data-driven approach enables intelligent decision-making, allowing manufacturers to optimize maintenance strategies, improve resource allocation, and enhance overall operational performance.
4. Streamlining operations: ISA-95 integration standardizes communication protocols and data formats, streamlining operations across the manufacturing enterprise. This standardization reduces the complexity of system integrations, making it easier to implement and manage advanced maintenance strategies.

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Challenges, complexities, and considerations

While integrating CMMS with ISA-95 offers significant benefits, it also presents several challenges and complexities that manufacturers must consider.

• System compatibility: Ensuring compatibility between CMMS and existing enterprise and control systems can be challenging. Manufacturers must evaluate their current infrastructure and potentially upgrade or modify systems to achieve seamless integration.
• Implementation costs: The initial cost of integrating CMMS with ISA-95 can be substantial. Manufacturers must invest in software, hardware, and training to successfully integrate. However, the long-term benefits in terms of efficiency and reliability often outweigh the initial investment.
• Organizational change: Integrating CMMS with ISA-95 may require changes in organizational processes and workflows. Employees need to be trained in new systems and procedures, and resistance to change may exist. Effective change management strategies are essential to ensure smooth implementation and adoption.

Although there are many potential challenges and considerations for integrating CMMS with ISA-95, the benefits prove to outweigh the challenges.

Integrating CMMS with ISA-95 drives the future of maintenance management

By leveraging the integration of CMMS and ISA-95, manufacturers can achieve enhanced efficiency and improved reliability and ultimately make better decisions to streamline their entire operations on the facility floor. While the process and integration have unique challenges, the long-term benefits make it a worthwhile investment for forward-thinking manufacturers.