In the first period of our meetup-series we introduced the Smart Factory, based on the 0-2 levels of the ANSI/ISA-95 model. We have presented the specifications of the discrete and the process manufacturing. Also showcased the industrial automation from the physical sensors to the SCADA/HMI systems from the Smart Factory's point of view.

1. REINVENT
POSSIBILITY
WITH
INDUSTRY X.0
SMART FACTORY
SESSION 1
Akos G. Garai
09/05/2019

2. Copyright © 2019 Accenture. All rights reserved. 2
Accenture is a LEADING GLOBAL PROFESSIONAL
SERVICES COMPANY

3. WE WORK ACROSS ALL ASPECTS OF INDUSTRIAL DIGITAL
TRANSFORMATION, WITH A WIDE RANGE OF BUSINESS
CAPABILITIES TO ADDRESS CLIENT CHALLENGES
Product X.0
Engineering X.0
Production &
Operations X.0
Innovation &
Technologies
Embedded
Software
Hardware
Engineering
Connected
Products
Digital TwinDigital Thread
Automation
Manufacturing
Execution
Systems
Advance
Planning &
Scheduling
Industrial
Internet of
Things
AI & Applied
Intelligence
Cyber
Security
Blockchain
Industrial E2E
Testing
Robotics
Product
Support
Services
Open Source
Governance
Compliance
AR/VR/XR
LIMS
Product
Lifecycle
Management
30+
clients
INDUSTRIAL AUTOMATION
CENTRE OF EXCELLENCE
More than
150 people
15+ years
R&D support and
innovation
3
Industry
groups
UX Design
Copyright 2019 Accenture. All rights reserved.

4. 4Copyright © 2019 Accenture. All rights reserved.
FROM SHOP-FLOOR TO TOP FLOOR
The BOTTOM-UP approach
HOW DOES A
MANUFACTURING
PLANT WORK
The components of a
functional
manufacturing plant
ANSI/ISA- 95
The standard for
developing interfaces
between enterprise and
process control systems
SMART PROCESS
CONTROL
How to design and code
process control for
smart manufacturing
DIGITAL
TRANSFORMATION
From OT to IT, the
roadmap from
traditional to smart
manufacturing

5. HOWDOESA
MANUFACTURING
PLANTWORK
THECOMPONENTSOFAFUNCTIONAL
MANUFACTURINGPLANT
Copyright © 2019 Accenture. All rights reserved. 5

6. • Sales / Demand
• Workforce resources (EHS/Training/Certification)
• Site utilities (Medium Voltage Distribution System, Compressed Air,
Refrigeration, Steam)
• In-, Out-bounding (Truck gates)
• Quality Control (Lab Information Management System)
• Warehousing (Warehouse Management System, Automated Storage and
Retrieval System)
• Material Movement (Automated Guided Vehicle, Transport Order Management)
• Maintenance (Computerized Maintenance Management System, Asset
Management, Preventive/Predictive Maintenance)
• Production Scheduling
• Production Lines
WHAT ARE THE COMPONENTS OF
MANUFACTURING IN A PLANT
Copyright © 2019 Accenture. All rights reserved. 6

7. ANSI/ISA-95
The standard for developing
interfaces between enterprise and
process control systems
Copyright © 2019 Accenture. All rights reserved. 7

8. THE INTERFACE BETWEEN ENTERPRISE AND
PROCESS CONTROL
ANSI/ISA-95
Copyright © 2019 Accenture. All rights reserved. 8
Enterprise-
Control System
Integration Part 2:
Object Model
Attributes
Enterprise-
Control System
Integration, Part
3: Models
of Manufacturing
Operations
Management
"Object models
and attributes for
Manufacturing
Operations
Management“
"Object models
and attributes for
Manufacturing
Operations
Management“
Enterprise-
Control System
Integration Part 1:
Models and
Terminology
ANSI/ISA-
95.00.01
2000
ANSI/ISA-
95.00.02
2001
ANSI/ISA-
95.00.03
2005
ISA-95.04 Object
Models &
Attributes Part 4
of ISA-95
In development
ISA-95.05 B2M
Transactions Part
5 of ISA-95
In development

9. A COMPLEX TAPESTRY OF INTERDEPENDENT INFORMATION SYSTEMS
OVERSEE MANUFACTURING BUSINESSES
FOUR /
FIVE
THREE
TWO
ONE
BUSINESS PLANNING /
BUSINESS INTELLIGENCE
Defines the business-related
activities needed to manage a
manufacturing organisation
MANUFACTURING
OPERATIONS
MANAGEMENT
Defines the activities of the work
flow to produce the desired end
products
CONTROLS &
AUTOMATION
Defines the activities of
monitoring and controlling the
physical processes
EQUIPMENT/DEVICES
Defines the activities involved in
sensing and manipulating the
physical processes
MANUFACTURING
IT SYSTEMS PYRAMID
ISA-95
LEVEL
DESCRIPTION
• Plant management
• Inventorymanagement
• Plant level prod. scheduling
• Detailed prod. scheduling
• ProductionTracking
• Quality assurance
• Visualisation / GUI
• Batch production control
• Continuous prod. control
• Discrete prod. control
• Productionprocess
ACTIVITIES
PRODUCTION MATERIALS
MACHINEPLANTENTERPRISE
STRATEGIC
Corporate
management
TACTICAL
Production
management
OPERATIONAL
Factoryfloor
control
NATURE OF
DECISIONS
What to
produce
What to
manufacture
ERP, CRM, APS
MES, WMS,
LIMS, ATS
SCADA, DCS
PLC, Production
Equipment,
Sensors, Robotics
PLM
INDICATIVE
SYSTEMS
Broad
Moderate
Broad
Broad
ADOPTION
TRANSACTIONAL
Days
Weeks
Months
Quarters
Years
TRANSACTIONAL
Seconds
Minutes
Hours
REAL-TIME
Sub-second
REAL_TIME
Sub-second
TIME
PERSPECTIVE
Moderate
What was
actually
produced
Real-time
status of
production
Copyright © 2019 Accenture. All rights reserved.

10. How to choose sensors/transmitters for the
given task
• What is the physical process
• What needs to be considered
• Inputs/outputs
• Voltage/Current/Load cell / Resistance / Others
• Environment / Abrasion / Corrosion
• Explosion Hazard (Ex / Atex)
• Connection Media (Wired / Wireless)
• Deception ( Influencing the signals)
THE ANSI/ISA-95 LEVEL-0:
PRODUCTION PROCESS
Copyright © 2019 Accenture. All rights reserved. 10
LEVEL 4
LEVEL 3
LEVEL 2
LEVEL 1
LEVEL 0

11. Sensing:
• Transmitters
• Others
Manipulating:
• Robots
• Actuators (Pneumatic/Hidraulic)
• Motors
– AC
– DC
– Soft Starters
– Servo Drives
• Others
THE ANSI/ISA-95 LEVEL-1:
SENSING AND MANIPULATING
Copyright © 2019 Accenture. All rights reserved. 11
LEVEL 4
LEVEL 3
LEVEL 2
LEVEL 1
LEVEL 0

12. Process Controllers:
• IIoT
• RTUs
• PLCs
• Others
THE ANSI/ISA-95 LEVEL-2:
MONITORING AND SUPERVISING
Copyright © 2019 Accenture. All rights reserved. 12
LEVEL 4
LEVEL 3
LEVEL 2
LEVEL 1
LEVEL 0

13. HMI/SCADA:
• The hallmarks of a good HMI/SCADA
Interface
• The „clean and ugly”
• The 2 meter rule
• The alarm frequency rule
• Situational awareness
• Historization and Big Data
• AI and Machine learning
THE ANSI/ISA-95 LEVEL-2:
MONITORING AND SUPERVISING
Copyright © 2019 Accenture. All rights reserved. 13
LEVEL 4
LEVEL 3
LEVEL 2
LEVEL 1
LEVEL 0

14. DIGITAL
TRANSFORMATION
From OT to IT, the roadmap from
traditional to smart manufacturing
Copyright © 2019 Accenture. All rights reserved. 14

15. • Changing the mindset
• Categorizing the needs
• Building use-cases
• Choosing what data is needed, what is relevant
• Building a roadmap
• Doing the work
• Manufacturing types
– Batch Processing
– Continuous Manufacturing
– Discrete Manufacturing
• Machine-to-Machine (M2M) vs. Industrial Internet of Things (IIoT)
– Machine vs. Sensor
– HW-based vs. SW-based
– Closed System vs. Open System
– Industry Standardized vs. Easy Integration
DIGITAL TRANSFORMATION:
IT / OT CONVERGENCE
Copyright © 2019 Accenture. All rights reserved. 15

16. SMARTPROCESS
CONTROL
How to design and code process
control for smart manufacturing
Copyright © 2019 Accenture. All rights reserved. 16

17. Copyright © 2019 Accenture. All rights reserved. 17
Process Controller:
• ~10ms loop time
• Controls the physical
process
– Independent
– Reliability / High Availability /
Redundancy
– Safety
• Keeps on or safely shuts
down the process in case of
external communication
loss
SMART PROCESS CONTROL:
PROCESS CONTROLLERS VS. SUPERVISORY
SYSTEMS
Supervisory System:
• ~1000ms loop time
• Displays and schedules the
processes, displays alarms.
– High availability / Redundancy
• Queues tasks in case of
connection loss

18. Follow ASNI/ISA-95
• Basic building blocks: Equipment Modules
• Built-in Simulation
• Firewall coding
• From EMs to PUs (Production Units)
• Interface design
• Grouping the PUs into Areas
• Colleting the Areas into Plants
SMART PROCESS CONTROLL:
SMART PROCESS CONTROL BY DESIGN 1/3
Copyright © 2019 Accenture. All rights reserved. 18

19. Higher level systems only connect to the PU or
EM interfaces only, never connect directly to
I/Os
• Simplified coding results in less errors/mistakes during
development and commissioning
• In case of modification of an EM or PU, then all the
equipment is affected at the same time, no need to
modify one-by-one
• For higher level system templates the interfaces on the
machine side are already present, there is no need for any
development.
SMART PROCESS CONTROLL:
SMART PROCESS CONTROL BY DESIGN 2/3
Copyright © 2019 Accenture. All rights reserved. 19

20. What if the design is not “smart”?
• Protocol Conversion
• Concentrators / Head-Controllers
• IIoT Gateways
• Reverse Engineering
• Multi-level data conversion
SMART PROCESS CONTROLL:
SMART PROCESS CONTROL BY DESIGN 3/3
Copyright © 2019 Accenture. All rights reserved. 20

21. Historian
• Process and recipe data logging
• Pattern recognition
• Predictive maintenance
• Process Improvement
MES/MOM
• Operations related process data management (logging,
reporting, reacting)
• Capacity improvement / OEE capture
Production scheduling
THE LEAP - OPENING POSSIBILITIES:
SMART PROCESS CONTROL MANUFACTURING
Copyright © 2019 Accenture. All rights reserved. 21

22. Q&A
Copyright © 2019 Accenture. All rights reserved. 22

23. THANKYOUFORYOUR
ATTENTION!
ÁkosG.Garai
akos.g.garai@accenture.com