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The Secret Life of S88‘Cause hey, everyone needs aanother acronym to remember
Russell Czolgosz (Chōl·gŏsh)
MTU ChE class of 1999Lead Automation and Controls
EngineerDow Corning CorpModified by DWC 1-11-2010
for CM4120
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 2
Background What is ISA and S88? Recipe Types 4-parts of the S88 Model
Physical Model Process Model Procedural Control Model Control Activity Model
Tying it all together
Outline
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 3
Need Predictable Product Quality Variation in feedstocks Poor control of manufacturing processes Human error Differences between processing locationsOvercome High Manufacturing Costs Low equipment utilization – difficulty in
scheduling Using old processing/control technologies Labor intensive High cost of energy Poor flow of material and informationWould Like New Markets/ New Products Need “Agility” but have a dedicated system Rigid design creates long product/process
development times
Typical Manufacturing Challenges
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 4
1. Design equipment for a specific process/ product
2. Develop procedures to make that product
3. Implement process control to meet the product requirements and fit the SOP
4. At completion all aspects of the SOP/ product/ equipment/ control are rigid, hard-coded, and fixed
This type of implementation:Hinders Process ImprovementProhibits Manufacturing AgilityPrevents Asset Optimization
The goal of S88 is to prevent these roadblocks.
Traditional Process Development
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 5
ISA – International Society of Automation S88 (or ISA 88) Batch Control Standard
Currently a 4-part standard Part 1 Models and Terminology (ANSI/ISA-88.01) Part 2 Data Structures & Guidelines for Languages
(ANSI/ISA-88.00.02) Part 3 General and Site Recipe Models &
Representation (ANSI/ISA-88.00.03) Part 4 Batch Production Records (ANSI/ISA-88.00.04) Part 5 is currently in draft
SP88 is the Batch Control Standards Committee
ISA S88 is...
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 6
The Intent of S88: Promotes modularity and flexibility Emphasizes good practices for design/
operation Provides a common concepts,
framework, models, and terminology Improve efficiency/ control of mfg.
plants (batch, semi-continuous, and continuous)
It is a guideline, NOT a compliance standard
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 7
S88 – Must be Interpreted!
S88 defines general practices Written to apply to the entire processing industry Makes suggestions and provides examples Does not list requirements
Suggests standardized modular design concepts Reusable design components Similar to object-oriented computer programming
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 8
Benefits of an S88 Solution?
1. Modularity allows for easier replication and better ROI
2. Design concepts make validation easier3. S88-aware solutions help track product
and process data4. Gathering requirements from customers/
conveying requirements to vendors is easier
5. Provides guidelines on how to recover from abnormal events
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 9
Spirit of S88
Not just a standard for software, equipment, or procedures A new way of thinking – a design philosophy
Understanding S88 will help you design better processes and manufacture better products Isolates equipment from recipes
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 10
Improved Batch Processing
Reduced batch cycle time
Increased production rate
Faster changeover More scheduled
recipes Reduced downtime Faster process
development Quicker product
launches
Reduced raw material loss
Improved batch consistency
Better equipment utilization
Less time to add/modify recipes
Lower engineering cost
Lower data capture cost
Better data availability
Throughput Cost
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 11
Steps in Applying S881. Learn the terminology2. Break the process down into
appropriate components3. Identify the steps necessary to
produce the product4. Identify recipe parameters5. Tie the recipe to the procedures6. Map the procedure to the processing
equipment
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S88 Recipe Types
What we want to make, what equipment we need, and how we want
to do it
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 13
4 Recipe Types
May be transformed into
General Recipe
Site Recipe
May be transformed into
Master Recipe
May be transformed into
Control Recipe
Ref. S88.01 Fig.8 – Recipe types
1. General Recipe Enterprise-wide Includes product-specific
processing information 2. Site Recipe
Specific to a site Includes site-specific information
(language, raw materials, on-site limitations, etc.)
3. Master Recipe Targeted to a specific cell Starting w/ a Site Recipe, is
adapted to Process Cell-specific equipment
4. Control Recipe Consists of a Master Recipe plus
Batch ID, batch size, etc. Forever tied to a particular batch
and is specific to that batch – permits product tracking
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A recipe holds the data that uniquely identifies the components of a specific product Ingredients to use Quantity of ingredients Equipment requirements The order in which tasks are performed
Recipes do not contain scheduling or equipment control information
Recipe Definition
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1. Process Model
2. Physical Model
3. Procedural Control Model
4. Control Activity Model
Applying S88 – 4 Models Defined
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 16
S88The Process Model
Describes the hierarchical ordering of process functionality needed to produce a
batch.
Is not equipment specific – very conceptual.
Used to develop the recipe procedures section in the General and Site Recipes
(high-level recipes).
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Process Model
Process Stage
Process Operation
Process
Process Action
General and Site Recipe procedures will be based on the “Process Model”
Consists of an ordered set of
Consists of an ordered set of
Consists of an ordered set of
Make PDMS
PolymerizeRemove Low BoilersCool Product
Prepare ReactorChargeReact
Add req’d 245 FluidAdd req’d EndblockerHeat to 140 C
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S88The Physical Model
The equipment used to perform the process.
Defines the hierarchy of the equipment.
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 19
Physical Model
Enterprise
Site
ProcessCell
Unit
AreaEquipment
Module
ControlModule
ProcessCell
Unit
EquipmentModule
ControlModule
MTU
Houghton
Chem Sci
Building
Consists of all the production and supporting equip necessary to make a batchA major piece of equipment within a process cell that performs a specific task
Grouping of equipment & control modules that together perform a minor task
Basic discrete and analog control (output) devices
PSCC
PDMS Reactor Unit
Solvent Recovery Unit
AgitatorTempFeedDischarge
Agitator Controls
Outlet valveTemp Controller
Subdivision of the corporation’s PHYSICAL ASSETS organized in a hierarchy of equipment that consists of several integrated levels
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An Example Process Cell
Mix
DischargeandRecirc
Pressure Control
Temperature Control
Material Charging
Material Selection
M
FT
TTPT
Pump
ControlModule
EquipmentModule
Unit
ProcessCell
FT
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 21
Defining a Unit Batching cannot occur without units
Batching occurs in units Units perform one or more major processing
activities A unit is used on only one batch at a time
A Unit runs a recipe Combine ingredients, or perform a reaction Adds value to your product or intermediate
Units function independently of each other
ControlModule
EquipmentModule
Unit
ProcessCell
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 22
Examples of Units:
Mix-making batch tank
Is a Unit
Is Not a Unit
Reactor
Pump
Ingredient storage tank
Washing machine
Kitchen blender
Refrigerator
Dishwasher
Pasteurizer
4
4
4
4
4
4
4
4
4
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Equipment Modules
Equipment modules group devices for performing one or more specific minor processing activities
Equipment modules run portion(s) of a recipe
Material Charging Equipment Module
FT
ControlModule
EquipmentModule
Unit
ProcessCell
MixM
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 24
Control Modules
Control modules “connect” software to the process through sensors and actuators
Act as a single entity from a control standpoint Carry out Basic Control – they do not contain
procedural control
ControlModule
EquipmentModule
Unit
ProcessCell
Temperature Control
TT
Material Selection
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 25
Physical Model is Collapsible
Although a process cell must contain at least one unit:
A control module does not have to be part of an equipment module to be part of a unit
A unit can “own” control modules directly
ControlModule
EquipmentModule
Unit
ProcessCell
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S88The Procedural Control
Model
Sequence of steps necessary to produce a batch.
Defines the sequential control that enables equipment to perform the
process task.
Used to develop the Recipe Procedures section of the Master Recipe
The specific control setpoints, quantities, controller modes, etc.
required to make a defined quantity of a certain product
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Procedural Control Model
Procedure
UnitProcedure
Operation
Phase
Defines the process strategy for making a batch within a process cell
- A hierarchy of the actions that are performed to complete a batch
Defines the actions that are performed on a Unit
- Consists of an ordered set of Operations that control the functions of the unit
Defines an ordered set of phases that are arranged to perform a particular function within a unit-One or more operations could occur simultaneously
Defines a simple action or command to set or change the state of an Equipment Module-Can be subdivided into steps and transitions
Add 245Add Endblocker
Prepare ReactorAdd IngredientsHeat
PolymerizeRemove Low BoilersCool Product
Make PDMS
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Procedural Control Model Example
MakeToothpaste
UnitProcedures
Operations
Phases
Procedure
Make Paste
PrepareTank
Add Water
Make Gel Swirl
AddIngredients
React
Add Fillers Add NaF
Phases are the workhorses.Other levels simply group,
organize, and direct phases.
Phases are the workhorses.Other levels simply group,
organize, and direct phases.
New Employee Training, Midland MIThe Secret Life of S88 29June 11, 2009
The Automation Specification:
A document that describes how Equipment Modulesare related to a Unit and how the Phase(s) control each Equipment Module
Control Module
Equipment Module
Unit
Process Cell
Area
Site
Enterprise
Phase
Operation
Unit Procedure
Procedure
Physical Model
Procedural Control Model
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S88 Models Tie Together thru Mapping
Relates the procedural control model to the physical model to provide the processing
described in the process model
Involves MAPPING of Procedural Elements into Physical Entities
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S88 – Model Relationships
+
Provides the functionality tocarry out a…
Ref. S88.01 Fig.7 – Procedural control/equipment mapping to achieve process functionality
Process Stage
Process Operation
ProcessProvides processfunctionality
to carry out a…
Unit(s)
Unit(s)
Unit(s)
Equipment Module(s)
Process Cell
Unit Procedure
Operation(s)
Phase(s)
Phase(s)
Procedure
+
CombinedWith a
=
=
=
+
+
Process Action
Process Action
Procedural Control Model Physical Model Process Model
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 32
Separation of Recipe, Procedures, Equipment/ Basic Control into separate models:
Each component is maintained as an entity Changes in the Recipe do not necessarily
require changes to the Phase Logic Changes to the Phase Logic do not
necessarily require changes to the Recipe Changes to physical equipment do not
necessarily require changes to the other models
Separate Models Add Flexibility
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 33
Corporate sends a General Recipe to my Site Convert General Recipe to a Site Recipe then Convert Site Recipe to a Master Recipe, for
each suitable cell, complete with setpoints, timing, quantities, tolerances, etc.
When we make a Batch, the Master Recipe gets transformed into a Control Recipe
allocate specific equipment create a batch identifier make the product, record all processing
parameters Control Recipe forever tied to that batch of
product
Summarizing the 1st Three Models
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 34
In our plant, we define: Physical Model (what Units and Equipment
Modules we have and the Basic Control that operates each)
Procedural Control Model (all the Phases that each Equipment Module can be in, what each Phase accomplishes, and the sequence of operations)
Mapping the Physical Model onto the Procedural Control Model produces the functionality described in the Process Model
Process Model describes what Process Actions will occur in each Phase of the process
Summarizing the 1st Three Models
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 35
Original Nestlé Toll House Chocolate Chip Cookies
Makes about 5 dozen cookies
Ingredients: 2 1/4 cups all-purpose flour1 teaspoon baking soda1 teaspoon salt1 cup (2 sticks) butter, softened3/4 cup granulated sugar3/4 cup packed brown sugar1 teaspoon vanilla extract2 large eggs2 cups (12-ounce package) NESTLÉ® TOLL HOUSE® Semi-Sweet Chocolate Morsels1 cup chopped nuts
Directions:
· PREHEAT oven to 375° F.
· COMBINE flour, baking soda and salt in small bowl.
· Beat butter, granulated sugar, brown sugar and vanilla extract in large mixer bowl until creamy.
· Add eggs one at a time, beating well after each addition.
· Gradually beat in flour mixture. Stir in morsels and nuts. Drop by rounded tablespoon onto ungreased baking sheets.
· BAKE for 9 to 11 minutes or until golden brown. Cool on baking sheets for 2 minutes; remove to wire racks to cool completely.
Operations
Procedure
Batch of Cookies!
FormulaInputs
Control Recipe
Phases
Recipe Parameters
Batch Size
Master Recipe
Transition Expression
Recipe Header
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 36
S88The Control Activity Model
The 4th Model
“Cactus Model”
Shows relationships between control activities
Describes flow of information throughout the enterprise
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 37
Control Activity Model
ProductionInformation
Management
RecipeManagement
ProductionPlanning andScheduling
ProcessManagement
UnitSupervision
ProcessControl
Personnel andEnvironmental
Protection
Below this line is outside S88 Scope
ProcessData
Batch and Process
Cell Information
Batch Progress
Batch Schedule
MasterRecipe
MasterRecipe
MasterRecipe
BatchSchedule
Batch and UnitInformation
Batch Status
Statuses
Statuses
Commands
Unit Recipes and Commands
Commands
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 38
Permits easy product customization Color, level of impurities, packaging, viscosity,
composition, etc. Facilitates rapid product change-over
Helps identify suitable assets at different sites
Allows for easy recipe conversion into local languages
Remember: S88 is only one element in a system of manufacturing
Overall Value of S88
New Employee Training, Midland MI June 11, 2009The Secret Life of S88 39
References
Applying S88 Batch Control from a User’s Perspective, Jim Parshall and Larry Lamb, ISA, Research Triangle Park, NC, 2000.
ISA S88.01-1995 (R2006) Batch Control Part 1: Models and Terminology, ISA, Research Triangle Park, NC, 2006.
World Batch Foundation, www.wbf.org International Society of Automation,
www.isa.org
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