ISA TR88.00.02-2022
Machine and Unit Status: An Implementation Example of ISA-88.00.01
- Standard No.
- ISA TR88.00.02-2022
- Release Date
- 2022
- Published By
- Instrument Society of America (ISA) US / ISA
- Latest
- ISA TR88.00.02-2022
- Introduction
Standard Background and Technical Evolution
ISA-TR88.00.02-2022 Technical Report is a key achievement of the International Society of Automation (ISA) for the standardization of discrete manufacturing equipment control. This standard builds on the ISA-88.00.01 Batch Process Control standard framework and is specifically extended and optimized for discrete manufacturing scenarios such as packaging, converting, and material handling.
The standard's evolutionary history shows that the 2015 version primarily simplified the document structure and clarified core concepts. The 2022 version further optimized the state model diagram based on real-world feedback, removed the "remote" interface, enhanced the PackTags configuration description capability, and provided more extensive schema definition examples.
Core State Model Architecture
The standard defines a complete state model based on automated machines, categorizing machine states into two main types: waiting states and executing states. A baseline state model consisting of 17 standard states is constructed.
State Type State Name State Value Function Description Minimum Required Waiting State STOPPED 2 The machine has stopped, waiting for reset command Yes IDLE 4 Reset completed, waiting for start command Yes ABORTED 9 Emergency stop completed, waiting for fault to be cleared Yes SUSPENDED 5 Suspending production due to external conditions No Execution status STARTING 3 Executing startup preparation steps No EXECUTE 6 Executing major processing activities Yes STOPPING 7 Executing controlled stop procedure No ABORTING 8 Executing emergency stop procedure No
Unit Control Mode Management
The standard defines four core control modes, allowing users to flexibly configure state model subsets based on different operational requirements:
Production Mode Application Case
In the production mode of the filling production line, the EXECUTE state corresponds to normal product production activities. When the upstream material supply is interrupted, the system automatically enters the SUSPENDING state, executes a controlled pause process, saves the current process parameters, and finally transitions to the SUSPENDED waiting state.
Once the material supply is restored, the system reloads the saved parameters through the UNSUSPENDING state and seamlessly returns to the EXECUTE state to continue production, minimizing production interruption time.
Control Mode Mode Value Main Purpose Typical State Configuration Production Mode 1 Normal Production Operation Complete state model, supports all standard conversions Maintenance Mode 2 Equipment Debugging and Fault Diagnosis Restricted state, independent of production line operation Manual Mode 3 Single Module Direct Control Basic state, supports jog and debugging User-defined mode 4-31 Special process requirements Custom state subset
PackTags standardized tag system
The standard defines a complete tag naming specification and divides machine interface data into three categories to ensure interoperability between devices from different manufacturers:
Tag category Main function Core tag example Data flow direction Command tag Receive external control instructions Command.UnitMode, Command.MachSpeed Input Status Tags Feedback on Current Operating Status Status.StateCurrent, Status.UnitModeCurrent Output Admin Tags Configuration and Monitoring Data Admin.AlarmHistory, Admin.CumulativeTimes Bidirectional Best Practices for Tag Implementation
In the Packaging Machinery implementation, Command.UnitModeChangeRequest is used to receive mode switch requests, Status.UnitModeCurrent feedbacks the current effective mode, and Status.UnitModeRequested displays the status of pending requests. This three-state mechanism ensures the reliability and state consistency of mode switching.
The Admin.CumulativeTimes[#].ModeStateTimes[#] structure provides detailed mode state time statistics, providing a standardized data basis for OEE calculation and equipment efficiency analysis.
State Transition Rules and Safety Assurance
The standard clearly defines the triggering conditions and execution rules for state transitions to ensure the consistency and predictability of machine behavior:
- Operator intervention: Sending status commands through local or remote interfaces
- Program element state response: Automatically triggered based on the internal logic conditions of the device
- Machine condition response: Hardware conditions such as material blockage and equipment failure
- Execution state completed: Automatic transition after the current state logic is executed
- Monitoring system intervention: Instructions from the upper-level MES or SCADA system
Key safety rules include: Mode switching must be performed in a state common to both modes to avoid simultaneous execution of state transition and mode switching, ensuring that the device is always in a controllable state.
Implementation Recommendations and Industry Applications
Based on experience with standard implementation, a layered implementation strategy is recommended:
- Basic Compliance Layer: Implements the minimum required states and basic PackTags to meet equipment monitoring needs
- Functional Completeness Layer: Implements a complete state model and tagging system to support advanced control functions
- Optimization and Extension Layer: Customizes user-defined modes and extended tags based on specific industry requirements
Production Line Integration Application
In the beverage filling production line, a unified PackML state model enables seamless integration of equipment such as fillers, labelers, and packaging machines. When upstream equipment enters the SUSPENDED state, downstream equipment automatically responds through Status.EquipmentInterlock, pausing the entire line in a coordinated manner to avoid material accumulation and equipment conflicts.
The unified Admin.ProductData[#] tag ensures the consistency of production data, provides a standardized data interface for the MES system, and significantly reduces the complexity of system integration.
The implementation of the standard not only improves the control standardization level of individual equipment, but more importantly, establishes a basic framework for the interconnection and interoperability of equipment throughout the entire factory, providing key technical support for intelligent manufacturing and Industry 4.0 transformation.
ISA TR88.00.02-2022 Referenced Document
- DIN 8782 Beverage packaging technology; terminology associated with filling plants and their constituent machines
- IEC 61131-1 Programmable controllers - Part 1: General information
- IEC 61131-3 Programmable controllers – Part 3: Programming languages
- ISO 22400 Automation systems and integration — Key performance indicators (KPIs) for manufacturing operations management — Part 2: Definitions and descriptions AMENDMENT 1: Key performance indicators for energy management
ISA TR88.00.02-2022 history
- 2022 ISA TR88.00.02-2022 Machine and Unit Status: An Implementation Example of ISA-88.00.01
- 2015 ISA TR88.00.02-2015 Machine and Unit States: An Implementation Example of ANSI/ISA-88.00.01
- 2008 ISA TR88.00.02:2008 MACHINE AND UNIT STATES: AN IMPLEMENTATION EXAMPLE OF ANSI/ISA-88.00.01
