ISO 18828-2:2016
(Main)Industrial automation systems and integration — Standardized procedures for production systems engineering — Part 2: Reference process for seamless production planning
Industrial automation systems and integration — Standardized procedures for production systems engineering — Part 2: Reference process for seamless production planning
ISO 18828-2:2016 describes a reference planning process for seamless production planning. The scope of the discussed reference process focusses on the planning of production systems such as make-to-stock or assemble-to-order production. The analysis of the process activities has been limited to those within the production planning. The following aspects are within the scope of ISO 18828-2:2016: · general overview of the reference planning process; · basic principles of the process model; · description of each level identified within the reference planning process for production planning; · structure of activities and relations within each planning discipline; · dependencies of interdisciplinary activities. The following items are outside the scope of ISO 18828-2:2016: · material requirement planning/manufacturing resource planning; · production order control; · production process; · early stage product design; · order management, inventory management, purchasing, transportation, warehousing; · production facilities planning/manufacturing facilities planning (physical plant and equipment), including any kind of resource that is not directly related to the manufacturing process; · value chain (inbound logistics, operations management, outbound logistics, marketing and sales); · resource visualization; · process simulation.
Systèmes d'automatisation industrielle et intégration — Procédures normalisées pour l'ingénierie des systèmes de production — Partie 2: Processus de référence pour la planification de la production sans couture
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INTERNATIONAL ISO
STANDARD 18828-2
First edition
2016-10-15
Industrial automation systems
and integration — Standardized
procedures for production systems
engineering —
Part 2:
Reference process for seamless
production planning
Systèmes d’automatisation industrielle et intégration — Procédures
normalisées pour l’ingénierie des systèmes de production —
Partie 2: Processus de référence pour la planification de la production
sans couture
Reference number
ISO 18828-2:2016(E)
©
ISO 2016
---------------------- Page: 1 ----------------------
ISO 18828-2:2016(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2016, Published in Switzerland
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form
or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior
written permission. Permission can be requested from either ISO at the address below or ISO’s member body in the country of
the requester.
ISO copyright office
Ch. de Blandonnet 8 • CP 401
CH-1214 Vernier, Geneva, Switzerland
Tel. +41 22 749 01 11
Fax +41 22 749 09 47
copyright@iso.org
www.iso.org
ii © ISO 2016 – All rights reserved
---------------------- Page: 2 ----------------------
ISO 18828-2:2016(E)
Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms, definitions and abbreviated terms . 2
3.1 Terms and definitions . 2
3.2 Abbreviated terms . 3
4 Reference model for production planning process . 3
4.1 Summary of the process A0 (level 1) . 5
4.2 Summary of the process A2 (level 2) . 6
4.2.1 Summary of the process A2.1 (level 3) . 8
4.2.2 Summary of the process A2.2 (level 3) .12
4.2.3 Summary of the process A2.3 (level 3) .16
4.2.4 Summary of the process A2.4 (level 3) .19
4.3 Associated planning functions.22
Annex A (informative) Summary of the associated planning functions .23
Annex B (informative) Production planning disciplines .26
Annex C (informative) Object-Process Diagram .29
Bibliography .31
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ISO 18828-2:2016(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www.iso.org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the meaning of ISO specific terms and expressions related to conformity assessment,
as well as information about ISO’s adherence to the World Trade Organization (WTO) principles in the
Technical Barriers to Trade (TBT) see the following URL: www.iso.org/iso/foreword.html.
The committee responsible for this document is Technical Committee ISO/TC 184, Automation systems
and integration, Subcommittee SC 4, Industrial data.
A list of all parts in the ISO 18828 series can be found on the ISO website.
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ISO 18828-2:2016(E)
Introduction
This document describes a reference planning process which aims to establish a consistent
understanding of production planning processes in the lifecycle stage of production preparation
addressing the phase in between design and manufacturing (see Figure 1). The primary application
domain of the reference planning process is planning of production systems, e.g. “make-to-stock” or
“assemble-to-order” production.
Investigations in the area of manufacturing lucidly show an increased utilization of digital planning
tools to master product and process complexity and respond to continuous cost and time pressure.
Production planning today uses many different IT-tools. These tools are mostly standalone solutions
that are highly oriented towards specific use cases. The isolation of the IT-tools hinders sustainable
system consistency. The heterogeneity and incompatibility of the IT systems hampers interdisciplinary
planning across multiple phases. A lack of clear structures for each phase leads, for example, to
inefficient planning and redundant processes, multiple work, transformation failures, and incomplete
information. The comparison of planning results, as well as information transfer between different
planning disciplines, is difficult. Despite this abundance of IT tools, as well as an overflow of various
process descriptions on all kind of specialized production domains in literature, a lack of common
standards is presently observable.
NOTE 1 For further reading, see Bibliography.
The reference planning process introduced within this document is illustrated in Figure 1. It is
embedded between the product design process and the production process. This illustration depicts
the sequential phases of the product life cycle, beginning with the concept phase, followed by the
evaluation of the product design until the start of manufacturing. It stresses the major importance of
a reference process for production planning as a link between product design and production itself. A
detailed visualization of the planning processes is given in Annex B.
Figure 1 — Classification of the reference planning process (qualitative depiction)
To achieve the goal of a consistent planning and harmonization of the multiple processes, the
development of a reference process for production planning is envisioned. Planning processes within
the manufacturing phase will be analysed and merged to optimize the efficiency and transparency
of each process activity. Thereby organizational, technological/technical and conceptual barriers are
identified and with appropriate measures minimized or totally eliminated.
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ISO 18828-2:2016(E)
In order to integrate IT systems across the multiple phases of product development, the processes used
in production planning need to be formalized and standardized.
For user specific applicability, the description of the model will be realized by the use of different
levels of detail. The reference planning process, as shown in Figure 1, comprises the totality of
processes within the production planning. Figure 2 depicts the reference planning process viewed
as an embedded process taking input information from earlier phases of the product life cycle (e.g. as
provided in ISO 10303-242) and releasing information such as work schedules to follow-up processes
(e.g. as described in ISO 10303-238). A general overview and a detailed explanation of all processes
within the reference planning process is given in Clause 4.
Figure 2 — Integration scenario of the reference planning process considering ISO 10303
Application Activity Modules (AAM)
NOTE 2 For further demarcation and possible integration to other standards considering industrial data, e.g.
product data (see ISO 10303-1), component data (see ISO 13584-1), production data (see ISO 15531-1) and life-
cycle data (see ISO 15926-1), see Bibliography.
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INTERNATIONAL STANDARD ISO 18828-2:2016(E)
Industrial automation systems and integration —
Standardized procedures for production systems
engineering —
Part 2:
Reference process for seamless production planning
1 Scope
This document describes a reference planning process for seamless production planning.
NOTE In this context, “seamless” means the consideration of multiple planning aspects (relevant planning
disciplines) within the product life cycle, as illustrated in Figure 1 and Figure B.1.
The scope of the discussed reference process focusses on the planning of production systems such as
make-to-stock or assemble-to-order production. The analysis of the process activities has been limited
to those within the production planning. The following aspects are within the scope of this document:
— general overview of the reference planning process;
— basic principles of the process model;
— description of each level identified within the reference planning process for production planning;
— structure of activities and relations within each planning discipline;
— dependencies of interdisciplinary activities.
The following items are outside the scope of this document:
— material requirement planning/manufacturing resource planning;
— production order control;
— production process;
— early stage product design;
— order management, inventory management, purchasing, transportation, warehousing;
— production facilities planning/manufacturing facilities planning (physical plant and equipment),
including any kind of resource that is not directly related to the manufacturing process;
— value chain (inbound logistics, operations management, outbound logistics, marketing and sales);
— resource visualization;
— process simulation.
2 Normative references
There are no normative references in this document.
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ISO 18828-2:2016(E)
3 Terms, definitions and abbreviated terms
3.1 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 15531-1 and the following apply.
3.1.1
container concept
explicit choice of a transport container, such as blister packs, lattice boxes or small parts containers
3.1.2
delivery concept
strategy adopted to supply individual parts, modules or finished products to the assembly and
manufacturing resources
3.1.3
product
thing or substance produced by a natural or artificial process
[SOURCE: ISO 10303-1:1994, 3.2.26]
3.1.4
production process management
planning process during the production phase
Note 1 to entry: After the start of production, the production process management is involved if process or
product changes (requests) occur which lead to a new planning iteration. It does not include the operation
planning, planning of materials and resources or the planning and control of production.
3.1.5
operating resources
movable and immovable resources that contribute to production
3.1.6
planning scenario
combination of certain planning variants from all planning disciplines
3.1.7
process chain
sequence of process activities
3.1.8
product design process
process of design of a product from the idea for a product through to the last engineering bill of
materials (EBOM)
3.1.9
product structure
structure providing a functional classification of all items, parts, components, sub-assemblies and
assemblies of a product
Note 1 to entry: The hierarchical “as-designed” product structure which is defined during product design allows
the creation of an engineering bill of materials (EBOM).
3.1.10
reference planning process
process from the initial product definition to delivery of the last work plan in series planning
Note 1 to entry: The reference planning process does not include production control.
Note 2 to entry: The initial product definition usually corresponds to the end of the concept phase.
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ISO 18828-2:2016(E)
3.1.11
work system
system used to fulfil a work task and described by the seven system terms (work task, work progress,
human, resource and equipment, input, output, environmental influences)
3.2 Abbreviated terms
assy assembly
BOM bill of materials
EBOM engineering bill of materials (BOM from the design perspective)
EOP end of production
ext extended
MBOM manufacturing bill of materials (BOM from the production perspective)
mfg manufacturing
PLC product life cycle
SADT structured analysis and design technique
SOP start of production
4 Reference model for production planning process
To provide information for different user groups and use cases, the reference process model for
production planning is based on a multi-level structure. The process is detailed by progressive stages
in a top down approach. The degree of abstraction decreases by drilling down the levels. The number
of available levels depends on the processes and the connected sub processes. Here, the main processes
are broken down into several sublevels. To reach an appropriate degree of abstraction, especially for the
main planning functions, five levels are defined. These levels are illustrated in Figure 3. The notation
of the elements within the process represents their respective model level in order to reach a better
orientation while going through the description of each process. Except for the root process A0 at model
level 0, each process refers to the model level according to the number of numeric digits in the notation
(e.g. the process A2.2.1 contains three numeric digits and belongs to the model level 3).
NOTE 1 Syntax and semantics are used according to the functional modelling language ANSI/IEEE 1320.1.
NOTE 2 A functional model describes the functions (e.g. activities, actions, processes, operations) of a system
(e.g. product design, production planning, production) and their relationships. The functional model represents
what is done rather than how it is done. The content of the model represents all possible functions of a system.
For company specific implementation not every function needs to be applied. Functional models such as activity
models are frequently used in normative context (see Bibliography).
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ISO 18828-2:2016(E)
Figure 3 — Structure of the reference planning process model
The consideration and control of the complexity are essential for the development of the reference
planning process. The modelling makes use of combining recurrent functions and constraints into
aggregated modules. As a result, clear structured planning processes consisting of input and output
data, control mechanism and methodical support have been modelled. Thereby both, functions at the
interface of the reference planning process and consolidations within the planning disciplines are
combined at the root level. This aggregation leads to a significant increase of clarity of description and
enables a prioritized view for the user at the given core discipline. The description of the detailed model
levels follows the same top down approach. First the level with the highest degree of abstraction will
be described (referred to as level 0), following a description of the level consisting of the main function
of the reference planning process. In reference to this basis every possible characteristic planning
element will be consecutively described. To ensure a consistent description of the different model levels
the detailed description of the levels contains the following structure:
— the graphical abstract of the detailed process activities using structured analysis and design
technique (SADT) notation;
— the textual description of the process activities;
— the additional explanation of specific model details.
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ISO 18828-2:2016(E)
4.1 Summary of the process A0 (level 1)
Figure 4 — Structure of the reference planning process at model level 1
Relating to the abstraction of the reference planning process, the starting point for the modelling of
the reference planning process are the constraints derived from the production planning. Beside
these constraints several control factors impact the production planning. As previously shown in
Figure 2, the constraints from higher levels are separated into different quantities and are provided
for the reference planning process. The product structure (EBOM), information about the raw parts
and several planning requirements are first level inputs derived from the production planning. The
control functions are represented by the framework conditions. Methodical support is provided for
every process. All information and processes combined constitute the output of the reference planning
process represented by the work schedule. Every iteration of the reference planning process leads to an
updated version of the work schedule and in the end to the last released work schedule. These iterations
are also represented in the detailed structure of the reference planning process as shown in Figure 4.
Due to the top down approach of the model the complexity of the considered process activities increases
for every level. To handle this complexity, the reference process for production planning is divided into
three main functions, described by the following:
— constraints within the product life cycle;
— core planning disciplines;
— associated planning functions.
The constraints within the product life cycle provide information for different planning disciplines and
associated planning functions through several levels of the model. The constraints operate as a control
function for other processes during the product life cycle. The constraints affect every element in every
level of the model (top down approach). Through the described structure the changes caused by the
decision making function can be precisely applied. The constraints provide planning requirements as
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ISO 18828-2:2016(E)
input information for the core planning disciplines, as well as control input for the associated planning
functions. Additional information needed in the detailed model levels that are not generated by the
remaining planning disciplines is provided by other requirements.
The core planning disciplines represent the considered planning function during production planning.
They receive the production information as controlled by the constraints and generate the planning
data output for the start of production. The core disciplines can contain various planning functions. In
the production planning field it is possible to distinguish between several types of planning disciplines.
The most important, fundamental planning disciplines are identified and detailed in the structure of
the reference process (see 4.2).
The core disciplines strongly interact with the associated planning functions and their constraints
from higher level. The constraints provide the external input and control parameters. The internal
consolidation of the output from the remaining planning functions is performed within the associated
planning functions (see A3 in Figure 4). The associated planning functions are able to realize
operations like the combination of the developed planning concepts during the different steps of
the production planning or the request for a management decision. Another essential aspect, which
is part of the associated planning function, is the production process management. The Production
process management runs parallel to production. If any changes to the planning requirements or other
constraints are necessary, the production process management is capable of triggering the iteration of
the preliminary planning steps to which the changes apply to.
4.2 Summary of the process A2 (level 2)
Figure 5 — Structure of the reference planning process at model level 1
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ISO 18828-2:2016(E)
When describing the production planning it is sensible to restrict these to the most important,
fundamental planning disciplines that can be found in many manufacturing companies. As shown in
Figure 5, these disciplines are:
— manufacturing planning;
— assembly planning;
— logistics planning;
— layout planning.
Each discipline will be structured by the degree of maturity of the planning. Thereby the manufacturing,
assembly, logistics and layout planning will be broken down into three subphases:
— concept planning;
— rough planning;
— detailed planning.
The structure based on the degree of maturity will be applied to all four core disciplines (see 4.2.1
to 4.2.4).
Manufacturing planning (A2.1) comprises all the measures taken in order to design a manufacturing
system, as well as the selection of the necessary manufacturing resources and processes. When
performing manufacturing planning, it is particularly important to take account dependencies with the
remaining planning disciplines such as assembly, logistics and layout planning.
Assembly planning (A2.2) defines the steps involved in the assembly of various individual parts to
create an end product and determines the necessary equipment (e.g. lifting cranes, robot arms). This
planning activity, which also includes the draft design of the assembly systems, is frequently performed
by the department which is responsible for work preparation.
The aim of logistics planning (A2.3) is to ensure that the raw materials and semi-finished products,
assemblies, subassemblies or fastening elements such as screws are available at the right place at the
right time and in the correct, economically optimized quantities.
As the last of the four focused planning disciplines, layout planning (A2.4) ensures that operating
resources are located optimally in the production area (e.g. the processes in an assembly line or
in an assembly cell can run as efficiently as possible). To perform this task, it is very important that
the knowledge and experience derived from the other planning disciplines is available during layout
planning.
NOTE For more detailed information about the core planning disciplines, see Annex B.
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ISO 18828-2:2016(E)
4.2.1 Summary of the process A2.1 (level 3)
Figure 6 — Structure of the manufacturing planning at model level 3
On this level (shown in Figure 6) the dependency between the assembly and the manufacturing
planning is shown. The output from the assembly planning is linked with the rough planning during
manufacturing planning. This connection provides the possibility for interaction between the two
planning disciplines. During the production planning, each planning discipline can progress at different
times and scales.
The production data inputs for the manufacturing planning, provided by the constraints from higher
level, are used in the concept planning phase (A2.1.1). With the assistance of the higher level constraints
the first concept data for the manufacturing planning is created. These are essentially inputs to generate
the manufacturing concepts (A2.1.2). The linking inputs for the rough manufacturing planning are the
necessary information needed to coordinate the different planning disciplines. With the assistance
of the interdisciplinary consolidation (see 4.3) the requested information is provided for the detailed
manufacturing planning (A2.1.3). This is the last phase of the manufacturing planning and the process
where the essential manufacturing information such as the manufacturing times, resources and costs
is detailed
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ISO 18828-2:2016(E)
4.2.1.1 Summary of the process A2.1.1 (level 4)
Figure 7 — Structure of the concept planning during manufacturing planning at model level 4
The main task of concept planning during manufacturing planning (as shown in Figure 7) is to collect
the necessary information provided by preliminary planning activities and prepare it in a useful
and consolidated form to create first manufacturing planning concepts. Different parameters, e.g.
framework conditions, strategic decisions or continuous improvement of production environment,
affect manufacturing planning at this early stage during the product life cycle (PLC).
The manufacturing planning develops conceptual designs and defines information about the
product structure, raw parts, planned number of pieces, shift models and resources (A2.1.1.1). After
the preparatory work has been completed, the manufacturing planning can be performed against
different scenarios. To do this, the material is allocated in a first step and an extended EBOM including
information about purchased parts is created. The material volumes and allocations are associated
to the manufacturing process activity regarding the necessary resources which are provided by the
constraints from higher level. An evaluation of the content and time required for the various working
operations is based on comparisons, the shift model and expert knowledge. This makes it possible to
estimate requirements in terms of employees, machines and work stations as a function of the planned
number of pieces (A2.1.1.2). Several manufacturing planning concepts will be developed and compared
without any great investment in terms of time and cost on the basis of this planning stage, which contains
only a very low level of detail (A2.1.1.3). Estimated relative manufacturing costs are created by making
use of the estimated manufacturing time per product and an extended manufacturing operation list.
This list contains additional information based on comparisons and estimations with other projects
(A2.1.1.4). The developed manufacturing concepts may differ for example in terms of used sequences
and/or innovative technologies. A manufacturing cost ranking which ranks the different concepts using
their relative costs builds the basis for choosing the preferred manufacturing plan (A2.1.1.5).
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ISO 18828-2:2016(E)
Several manufacturing concepts, the manufacturing process graph, a manufacturing cost ranking and
the estimated manufacturing time for each product represent the final result of concept planning. It is
created by this phase and handed over to the rough planning
...
DRAFT INTERNATIONAL STANDARD
ISO/DIS 18828-2
ISO/TC 184/SC 4 Secretariat: ANSI
Voting begins on: Voting terminates on:
2015-09-07 2015-12-07
Industrial automation systems and integration —
Standardized procedure for production systems
engineering —
Part 2:
Reference process for seamless production planning
Titre manque
ICS: 25.040.40
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
THEREFORE SUBJECT TO CHANGE AND MAY
NOT BE REFERRED TO AS AN INTERNATIONAL
STANDARD UNTIL PUBLISHED AS SUCH.
IN ADDITION TO THEIR EVALUATION AS
BEING ACCEPTABLE FOR INDUSTRIAL,
TECHNOLOGICAL, COMMERCIAL AND
USER PURPOSES, DRAFT INTERNATIONAL
STANDARDS MAY ON OCCASION HAVE TO
BE CONSIDERED IN THE LIGHT OF THEIR
POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN
Reference number
NATIONAL REGULATIONS.
ISO/DIS 18828-2:2015(E)
RECIPIENTS OF THIS DRAFT ARE INVITED
TO SUBMIT, WITH THEIR COMMENTS,
NOTIFICATION OF ANY RELEVANT PATENT
RIGHTS OF WHICH THEY ARE AWARE AND TO
©
PROVIDE SUPPORTING DOCUMENTATION. ISO 2015
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ISO/DIS 18828-2:2015(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2015, Published in Switzerland
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form
or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior
written permission. Permission can be requested from either ISO at the address below or ISO’s member body in the country of
the requester.
ISO copyright office
Ch. de Blandonnet 8 • CP 401
CH-1214 Vernier, Geneva, Switzerland
Tel. +41 22 749 01 11
Fax +41 22 749 09 47
copyright@iso.org
www.iso.org
ii © ISO 2015 – All rights reserved
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ISO / DIS 18828-2:2015(X)
Contents
Foreword .iv
Introduction. v
1 Scope . 1
2 Normative references . 2
3 Terms and definitions . 2
4 Reference model for production planning process . 6
4.1 Summary of the process A0 (level 1) . 7
4.2 Summary of the process A2 (level 2) . 9
4.3 Associated planning functions . 27
Annex A (normative) Summary of the associated planning functions . 28
Annex B (informative) Production planning disciplines . 31
Annex C (informative) Object Process Diagram . 34
Bibliography . 37
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ISO / DIS 18828-2:2015(X)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national
standards bodies (ISO member bodies). The work of preparing International Standards is normally
carried out through ISO technical committees. Each member body interested in a subject for which a
technical committee has been established has the right to be represented on that committee.
International organizations, governmental and non-governmental, in liaison with ISO, also take part in
the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all
matters of electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2. www.iso.org/directives
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received. www.iso.org/patents
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
The committee responsible for this document is ISO/TC 184, Automation Systems and
Integration, Subcommittee SC 4, Industrial data.
ISO 18828 consists of the following parts, under the general title Standardized procedures for production
systems engineering
— Part 2: Reference process for seamless production planning
The following parts are under preparation:
— Part 1: Overview, concepts and integration
— Part 3: Information management of seamless production planning – Information flow within
production systems engineering
— Part 4: Measurability of production planning processes – Key performance indicators for production
systems engineering
— Part 5: Manufacturing change management
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ISO / DIS 18828-2:2015(X)
Introduction
This part of ISO 18828 describes a reference planning process which aims to establish a consistent
understanding of production planning processes in the lifecycle stage of production preparation
addressing the phase in between design and manufacturing (see Figure 1). The primary application
domain of the reference planning process is process planning for serial production systems.
Investigations in the area of manufacturing lucidly show an increased utilization of digital planning
tools to master product and process complexity and respond to continuous cost and time pressure.
Production planning today uses many different IT-tools. These tools are mostly standalone solutions
that are highly oriented towards specific use cases. However, the isolation of the IT-tools hinders
sustainable system consistency. The heterogeneity and incompatibility of the IT systems hampers
interdisciplinary planning across multiple phases. A lack of clear structures for each phase leads to
inefficient planning and redundant processes, multiple work, transformation failures, incomplete
information etc. In addition, the comparison of planning results as well as information transfer between
different planning disciplines is difficult. Despite this abundance of IT tools as well as an overflow of
various process descriptions on all kind of specialized production domains in literature, a lack of
common standards is presently observable.
NOTE For further readings see Bibliography
The reference planning process introduced within this document is illustrated in Figure 1. It is
embedded between the product design process and the production process. This illustration depicts the
sequential phases of the product life cycle, beginning with the concept phase, followed by the evaluation
of the product design until the start of manufacturing. It furthermore stresses the major importance of a
reference process for production planning as a link between product design and production itself. A
detailed visualization of the planning processes is given in Annex B.
Reference
Product Design
Planning
Process
Production Planning
Production
Product Lifecycle
Manu-
Concept Design In Service Disposal
facturing
Figure 1 — Classification of the reference planning process (qualitative depiction)
To achieve the goal of a consistent planning and harmonization of the multiple processes, the
development of a reference process for production planning is therefore envisioned. Planning processes
within the manufacturing phase will be analyzed and merged to optimize the efficiency and
transparency of each process activity. Thereby organizational, technological/technical and conceptual
barriers are identified and with appropriate measures minimized or totally eliminated.
In order to integrate IT systems across the multiple phases of product development, it is therefore
necessary to formalize and standardize the processes used in production planning.
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ISO / DIS 18828-2:2015(X)
Automation Systemes and Integration — Standardized procedures
for production systems engineering —
Part 2:
Reference process for seamless production planning
1 Scope
This document describes a reference planning process for seamless production planning. The scope of
the discussed reference process focusses on the production planning for products in serial production.
The analysis of the process activities has been limited to those within the production planning. The
following aspects are within the scope of this document:
— General overview of the reference planning process
— Basic principles of the process model
— Description of each level identified within the reference planning process for production planning
— Structure of activities and relations within each planning discipline
— Dependencies of interdisciplinary activities
Develop Product
(AP 242)
Data Models
Product Structure
Concept
Development
(AP 242)
Lifecycle Requirements
Reference
Manufacture
Planning Process
Manufacture
Product
Product
(AP 238)
e.g. Work Plan
(AP 238)
Raw Parts
Information
from AAM
Figure 2 — Integration scenario of the reference planning process considering ISO 10303 AAM
NOTE For further demarcation and possible integration to other standards considering industrial data e.g.
product data (ISO 10303), component data (ISO 13584), production data (ISO 15531) and life-cycle data (ISO
15926) see Bibliography
For user specific applicability the description of the model will be realized by the use of different levels
of detail. The reference planning process, as shown in Figure 1 comprises the totality of processes
within the production planning. Additionally Figure 2 depicts the reference planning process viewed as
an embedded process taking input information from earlier phases of the product life cycle provided for
instance in STEP AP 203/214/242 etc. and releasing information such as work schedules to follow-up
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ISO / DIS 18828-2:2015(X)
processes (such as described in STEP AP 238). A general overview and a detailed explanation of all
processes within the reference planning process follow in Section 0.
The following items are out of scope:
— Material requirement planning / manufacturing resource planning
— Production order control
— Production process
— Early stage product design
— Order management, inventory management, purchasing, transportation, warehousing
— Production facilities planning/ manufacturing facilities planning (physical plant and equipment);
that includes any kind of resource that is not directly related to the manufacturing process
— Value chain (inbound logistics, operations management, outbound logistics, marketing and sales)
— Resource visualization
— Process simulation
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
ANSI/IEEE 1320.1 (2004-00-00), Functional Modeling Language - Syntax and Semantics for IDEF0
3 Terms and definitions
3.1 Terms defined in ISO 10303-1
This part of ISO 18828 makes use of the following terms defined in ISO 10303-1:
— product
3.2 Terms defined in ISO 15531-1
This part of ISO 18828 makes use of the following terms defined in ISO 15531-1:
— manufacturing
— manufacturing management
— manufacturing planning
— manufacturing process
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ISO / DIS 18828-2:2015(X)
— master production schedule
— master production scheduling
— process
— process planning
— production control
— production facilities; manufacturing facilities
— production order control
— resource
— resources requirements planning; rough cut capacity planning (RCCP)
— scheduling
3.3 Other terms and definitions
For the use of this document the following terms and definitions apply.
3.3.1
Container concept
The explicit choice of a transport container, such as blister packs, lattice boxes or small parts containers.
3.3.2
Delivery concept
Strategy adopted to supply individual parts, modules or finished products to the assembly and
manufacturing resources.
3.3.3
Delivery concept
Strategy adopted to supply individual parts, modules or finished products to the assembly and
manufacturing resources.
3.3.4
Feasibility
Technical feasibility
3.3.5
Production process management
The planning process during the production phase. After the start of production the production process
management is involved if process or product changes (requests) occur which lead to a new planning
iteration. It does not include the operation planning, planning of materials and resources or the
planning and control of production.
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ISO / DIS 18828-2:2015(X)
3.3.6
Operating resources
Movable and immovable resources that contribute to production.
3.3.7
Planning of machines, facilities and equipment
Definition, quantity, specifications, and technical specifications of required machines, facilities, and
operating resources, as well as planning the required capacity.
3.3.8
Planning scenario
Combination of certain planning variants from all planning disciplines
3.3.9
Process chain
Sequence of process activities
3.3.10
Product design process
The process of design a product from the idea for a product through to the last EBOM.
3.3.11
Product Structure (EBOM)
The product structure provides a functional classification of all items, parts, components, sub-
assemblies and assemblies of a product. The hierarchical “as-designed” product structure which is defined
during product design allows the creation of an engineering bill of materials (EBOM).
3.3.12
Reference planning process (for production planning)
Process from the initial product definition – usually from the end of the concept phase – to delivery of
the last work plan in series planning. It does not include production control.
3.3.13
Work system
Used to fulfill a work task and is described by the seven system terms (work task, work progress,
human, resource and equipment, input, output, environmental influences).
3.5 Abbreviations and descriptions
For the use of this document the following abbreviations and descriptions apply.
3.5.1
Assy
Assembly
3.5.2
BOM
Bill of materials
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ISO / DIS 18828-2:2015(X)
3.5.3
CAD
Computer-aided design
3.5.4
CNC
Computerized numerical control
3.5.5
EBOM
Engineering BOM (BOM from the design perspective)
3.5.6
est
estimated
3.5.7
Ext
Extended
3.5.8
MBOM
Manufacturing-BOM (BOM from the production perspective)
3.5.9
Mfg
Manufacturing
3.5.10
PLC
Product life cycle
3.5.11
SADT
Structured Analysis and Design Technique
3.5.12
SOP
Start of production
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ISO / DIS 18828-2:2015(X)
4 Reference model for production planning process
To provide information for different user groups and use cases, the reference process model for
production planning is based on a multi-level structure. The process is detailed by progressive stages in
a top down approach. The degree of abstraction decreases by drilling down the levels. The number of
available levels depends on the processes and the connected sub processes. Here, the main processes
are broken down into several sublevels. To reach an appropriate degree of abstraction, especially for
the main planning functions, five levels are defined. These levels are illustrated in Figure 3. The
notation of the elements within the process represents their respective model level in order to reach a
better orientation while going through the description of each process. Except for the root process A0 at
model level 0, each process refers to the model level according to the number of numeric digits in the
notation (for instance: the process A2.2.1 contains three numeric digits and therefore belongs to the
model level 3).
NOTE Syntax and Semantics are used according to the functional modeling language ANSI/IEEE 1320.1.
Level 0
A0
Reference planning process
Level 1
A
A2 A3
1
Constraints Core planning Associated planning
functions
within PLC disciplines
Level 2
A2.1 A2.2 A2.3 A2.4 A3.1 A3.2
Manufacturing Assembly Logistic Layout Interdisciplinar High level
planning planning planning planning y consolidation planning
Level 3
A3.2.1 A3.2.2
…
A2.1.1 A2.1.2 A2.1.3
Concept Rough Detailed
A2.2.1 A2.2.2 A2.2.3 A2.3.1 A2.3.2 A2.4.1 A2.4.2 A2.4.3
manu- manu- manu- Concept Rough Detailed Rough Detailed Concept Rough Detailed
facturing facturing facturing
assembly assembly assembly logistic logistic layout layout layout
planning planning planning planning planning planning planning planning planning planning planning
Level 4
A2.2.2.1 A2.2.2.2 A2.2.2.3 A2.2.2.4
…
= process activity
Figure 3 — Structure of the reference planning process model
The consideration and control of the complexity are essential for the development of the reference
planning process. The modeling makes use of combining recurrent functions and constraints into
aggregated modules. As a result, clear structured planning processes consisting of input and output
data, control mechanism and methodic support have been modelled. Thereby both, functions at the
interface of the reference planning process and consolidations within the planning disciplines are
combined at the root level. This aggregation leads to a significant increase of clarity of description and
enables a prioritized view for the user at the given core discipline. The description of the detailed model
levels follows the same top down approach. First the level with the highest degree of abstraction will be
described (referred to as level 0), following a description of the level consisting of the main function of
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ISO / DIS 18828-2:2015(X)
the reference planning process. In reference to this basis every possible characteristic planning element
will be consecutively described. To ensure a consistent description of the different model levels the
detailed description of the levels contains the following structure:
— The graphical abstract of the detailed process activities using SADT notation
— The textual description of the process activities
— The additional explanation of specific model details
4.1 Summary of the process A0 (level 1)
Technical f easibility Framework conditions
Continuous improv ement of production env ironment
Resources
Change request
Decisions request
Decisions request
Necessary resources
Modif ications
Scenario criteria
Other requirements
Constraints
Planning
within
requirements
product
life Planned number of pieces
Logistics concepts
cycle
Defined layout
Shif t models MBOM-input
Core planning Mfg. times
disciplines Released work
Associated
Internal logistics concept
Time data per product
schedule
planning
Assy . times
A1
f unctions
Combined
Manufacturing concepts
Raw parts
concepts
Assembly concepts
Product structure (EBOM)
Adjusted
Layout concepts
planning
Ergonomics v alidation
scenario
Costs
A2 Cycle
times
A3
Methodic support
NODE: TITLE: NUMBER:
Reference Planning Process
Model level 1
A0
Figure 4 — Structure of the reference planning process at model level 1
Relating to the abstraction of the reference planning process, the starting point for the modeling of the
reference planning process are the constraints derived from the production planning. Beside these
constraints several control factors impact the production planning. As previously shown in Figure 2 the
constraints from higher levels are separated into different quantities and are provided for the reference
planning process. The product structure (EBOM), information about the raw parts and several planning
requirements are first level inputs derived from the production planning. The control functions are
represented by the framework conditions. Additionally methodic support is provided for every process.
All information and processes combined constitute the output of the reference planning process
represented by the work schedule. Every iteration of the reference planning process leads to an
updated version of the work schedule and in the end to the last released work schedule. These
iterations are also represented in the detailed structure of the reference planning process as shown in
Figure 4.
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ISO / DIS 18828-2:2015(X)
Due to the top down approach of the model the complexity of the considered process activities
increases for every level. To handle this complexity the reference process for production planning is
divided into three main functions described by the
— Constraints within the product life cycle,
— Core planning disciplines and,
— Associated planning functions.
The constraints within the product life cycle provide information for different planning disciplines and
associated planning functions through several levels of the model. The constraints operate as a control
function for other processes during the product life cycle. The constraints affect every element in every
level of the model (top down approach). Through the described structure the changes caused by the
decision making function can be precisely applied. Furthermore the constraints provide planning
requirements as input information for the core planning disciplines as well as control input for the
associated planning functions. Therefore additional information needed in the detailed model levels
that are not generated by the remaining planning disciplines, are provided by other requirements.
The core planning disciplines represent the considered planning function during production planning.
They receive the production information as controlled by the constraints and generate the planning
data output for the start of production. The core disciplines can contain various planning functions. In
the production planning field it is possible to distinguish between several types of planning disciplines.
The most important, fundamental planning disciplines are identified and detailed in the structure of the
reference process (see Section 4.2).
The core disciplines strongly interact with the associated planning functions and their constraints from
higher level. The constraints provide the external input and control parameters. The internal
consolidation of the output from the remaining planning functions is performed within the associated
planning functions (A3 in Figure 4). The associated planning functions are able to realize operations
like the combination of the developed planning concepts during the different steps of the production
planning or the request for a management decision. Another essential aspect, which is part of the
associated planning function, is the production process management. The Production process
management runs parallel to production. If any changes to the planning requirements or other
constraints are necessary, the production process management is capable of triggering the iteration of
the preliminary planning steps to which the changes apply to.
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ISO / DIS 18828-2:2015(X)
4.2 Summary of the process A2 (level 2)
Necessary
resources
Modif ications
Detailed linking concept
Manufacturing concepts
Raw parts
EErrggoonnoommiiccss vv aalliiddaattiioonn
Product structure (EBOM)
DDDDeeeecccciiiissssiiiioooonnnnssss rrrreeeeqqqquuuueeeesssstttt
Time data per product
CChhaannggee rreeqquueesstt
Planned number
RReessoouurrcceess
Manufacturing
of pieces CCoossttss
planning
Shif t models Mfg. times
MMBBOOMM--iinnppuutt
Adjusted
planning scenario
Assy . times
Logistics
A2.1
concepts
Assembly
Assembly
planning
concepts
Precedence graph
Detailed linking concept
A2.2
Layout
Cycle times
concepts
Logistics
Layout
planning
planning
Internal logistics
Defined
concept
layout
A2.3
Combined concepts
A2.4
Other requirements
Methodic support
NODE: TITLE: NUMBER:
Core planning disciplines
Model level 2
A2
Figure 5 — Structure of the reference planning process at model level 1
When describing the production planning it is sensible to restrict these to the most important,
fundamental planning disciplines that can be found in many manufacturing companies. As shown in
Figure 5, these disciplines are:
— Manufacturing planning
— Assembly planning
— Logistics planning and
— Layout planning
Each discipline will be structured by the degree of maturity of the planning. Thereby the manufacturing,
assembly, logistics and layout planning will be broken down into three subphases:
— Concept planning
— Rough planning
— Detailed planning
The structure based on the degree of maturity will be applied to all four core disciplines (Section 4.2.1
to Section 4.2.4).
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ISO / DIS 18828-2:2015(X)
Manufacturing planning (A2.1) comprises all the measures taken in order to design a manufacturing
system as well as the selection of the necessary manufacturing resources and processes. When
performing manufacturing planning, it is particularly important to take account dependencies with the
remaining planning disciplines such as assembly, logistics and layout planning.
Assembly planning (A2.2) defines the steps involved in the assembly of various individual parts to create
an end product and determines the necessary equipment (lifting cranes, robot arms, etc.). This planning
activity, which also includes the draft design of the assembly systems, is frequently performed by the
department which is responsible for work preparation.
The aim of logistics planning (A2.3) is to ensure that the raw materials and semi-finished products,
assemblies, subassemblies or fastening elements such as screws are available at the right place at the
right time and in the correct, economically optimized quantities.
As the last of the four focused planning disciplines, layout planning (A2.4) ensures that operating
resources are located optimally in the production area (e. g. the processes in an assembly line or in an
assembly cell can run as efficiently as possible). To perform this task, it is very important that the
knowledge and experience derived from the other planning disciplines is available during layout
planning.
NOTE for more detailed information about the core planning disciplines see Annex B
4.2.1 Summary of the process A2.1 (level 3)
Modif ications
Necessary
resources
Planned number of pieces
Shif t models
Est. mfg. time per
product
Change request
Product structure (EBOM)
Concept planning
Sev eral mfg.
Decisions request
Raw parts during
planning concepts
manuf acturing
Manufacturing concepts
Other requirements planning
Manufacturing
Allocated mf g. resources
process graph
Rough planning
Mfg. cost ranking
during
First mfg. cost calculation
manuf acturing
A2.1.1
planning
Manufacturing plan Mfg. times
Assy . times
Manufacturing
Resources
Time data
process time
per product
MBOM-input
Detailed planning
Detailed linking
during
concept
A2.1.2
Detailed linking concept
manuf acturing
planning
Adjusted planning Ergonomics v alidation
scenario
Costs
A2.1.3
Methodic support
NODE: TITLE: NUMBER:
Manufacturing planning
Model level 3
A2.1
Figure 6 — Structure of the manufacturing planning at model level 3
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ISO / DIS 18828-2:2015(X)
On this level (shown in Figure 6) the dependency between the assembly and the manufacturing
planning is shown. The output from the assembly planning is linked with the rough planning during
manufactur
...
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