CT531 Batch Management Control - Rockwell … oryTalk Batch 12 pe Release to Production Workflow sily manage your recipe release workflow process by providing a clear ocess workflow

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E

PUBLIC INFORMATION

CT531 – Batch Management & Control

2015 RAOTM

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 3

Agenda

Procedural execution Information

Automated and manual procedural activities

FTBatch System

S88 Fundamental concepts

Process and Procedures

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION

Batch

ContinuousDiscrete

Process and Procedures


Enables you to increase the success of your manufacturing operations

Continuous

Batch

Discrete

Enforce

Specify

Verify

Procedure management for the Process industry


Overview of

6

The FactoryTalk Batch Software Suite empowers you to standardize product definitions, improve product quality, simplify product development, speed up system deployment, and reduce implementation cost and risk.FactoryTalk Batch Software Suite provides: Operators - the view to effectively control the process Production - the information to understand what’s happening on the plant floor Recipe authors - an environment to easily build and manage product recipes Management - the information needed to make sound business decisions Quality - the information needed to improve the process and meet compliance

requirements Maintenance - the tools required to quickly diagnose problems System designers - the tools to support modular batch automation using industry

standards Engineers - the ability to seamlessly integrate the software to the control system


“ SEPARATE ”

Equipment ModelProcedure Model EquipmentProcedureWhat are the

Personnel and Equipment capabilities?

What to do with the equipment ?

S88 Fundamental concepts


JRP

AGITATE

JRP

ADD_MAT_B

JRP

TRANSFER OUT

JRP

ADD_MAT_A

JRP

TEMP_CTRL

JRP

ADD_WATER

JRP

ADD_MANUAL

Equipment Capabilities Units / Phases

What is the equipment capable of doing?

Hint: Look for Verbs / Actions


- Product A - Product B

Many Products “No Code Change Required”

JRP

ADD_MAT_B

JRP

TRANSFER OUT

JRP

ADD_MAT_A

JRP

TEMP_CTRL

JRP

ADD_WATER

JRP

ADD_MANUAL

JRP

AGITATEJRP

ADD_MAT_BJRP

AGITATE

JRP

AGITATEJRP

TEMP_CTRL

JRP

TRANSFER OUT

What to do with the equipment ?


Recipe Formulator Uses:

Recipe Phases Equipment Phases

Control Engineer Creates:

Recipe Phase & Equipment PhaseExample

Equipment ModelProcedural Model

JRP

Heat

TT

PARAMETERS

JRP

Heat

JRP JRP

REPORT DATA


Phase Manager Logic definition

+ = Parameters Report Values Execution logic

Controller firmware Phase infrastructure Phase tags State transition logic Phase logic interface

Equipment Phase

Reusable Modular code

11

FTBatch System


Equipment editorUse the Editor to Create Units, Phase classes and instances

Synchronize with controller to create each phase instance code structure


WeighMixerReactor

System OverviewEditors


What to do with the equipment?

Formulator Aspects (Modularity)

• Product recipes• Experimental Recipes• Cleaning / Steaming (CIP /SIP) recipes• Material Qualification recipes• Equipment setup procedures• Dispensing procedures• Startup sequences• Shut down sequences• Abnormal state handling Sequences• Etc.

Manual and Automated Procedures come together


Formulator aspectsIntelligent recipe formulas values

Recipe author's can write parameter, transition, & binding expressions to create “intelligent” recipes that reference unit tags, attributes, input/output parameters.

Options to define report parameters at all levels of the recipe including phase, operation, unit procedure, and procedure.

Phase report parameters give you the ability to accumulate values uploaded by phase logic.

erations aspectsch Security)

cation securityser authentication at Logon

mand Authorization security ull access control to operations nsures that personnel are prompted for

signatures when commands are executed. meter and Report deviation authorizationanual and Automatic Phaseshree Levels of limit values can be securedronic Signaturesp to three signatures for authorizationogs intent of each signatureull names logged in event journal

Limits and values displayed

Required Signatures, * is the last one to sign

2

oryTalk Batch 12pe and Area Model Security

ecipe procedures encapsulate the best practices in performing your ocessing tasks

The value of these recipes often contain your competitive differentiatorsControlling the unauthorized distribution of this information is paramount.

otect your recipes and equipment model ntellectual property by assigning them a

Security Token Identifier generated by your system

NEW

2

oryTalk Batch 12pe Release to Production Workflow

sily manage your recipe release workflow process by providing a clear ocess workflow definition and visibility for each recipeforce signoffs prior to releasing the recipe as a “step” or to productionferent signature templates are created and a workflow is configuredch recipe will log its signoffs

NEW

r compliance with Good anufacturing Practices (GMP), easing or removing a master cipe to/from production requires e consensus of multiple keholders

2

oryTalk Batch 12pe Versioning

ersion control simplifies managing and acking recipes

Allows recipe authors to save and retrieve versions of a recipeOnce a recipe is checked in it can’t be alteredIt can be checked out as a “work in progress” (WIP) and then checked in

s recipe procedures evolve:Keep track of the genealogy of your procedural filesRecall how a product was manufacturedCarry out experimental procedures and get back to an earlier version if required

Operation_A

Operation_A 1. New / Save as

2. Save

Operation_A3. Save

Operation_A~V14. Check IN

Operation_A~V2_WIP5. Check OUT

Operation_A~V3_WIP 7. Check IN

Operation_A~V2

Operation_A~V4_WIP

8. Check OUT

Operation_A~V49. Check IN

6. Check OUT

10. Check IN

NEW

Editors Run Time

tomated and manual procedural activities

gineering Aspects sable code and templates)

Display components / Controller code

gineering Aspects sable code and templates)

stem OverviewEditors Run Time

P / MES

API Call

M l A ti iti

eduling Batches

A t t d A ti itiperator

mple, A 13,000 liter campaign size is created with a batch size of 5,000 liters.ith Allow Single Odd-Sized Batch selected, there will be two batches at 5,000ers and a single (third) batch created with a batch size of 3,000 liters, thus fulfilling

ble batch/campaign creationdd individual batches – you can specify the size of each batch in the campaign.reate campaigns with multiple batches – you can automatically generate the campaign of tches using the quantity/size or a value in between that is applied to all batches in the mpaign.

heduling Aspectsh campaign)

e enabling technology to build equipment nit) binding requirements and preferences o procedures.

cisions can be based on:PreferenceRequirement

e “Smart Binding” to address:Cost Concerns (use the “warmest” reactor)Clean-in-place Requirements (“peanut-free” product)Out-of-Service Status (scheduled maintenance)Unit/Recipe Compatibility (Glass Lined Reactors)Avoid using Unit with unneeded functionality (recipe doesn’t need agitator)

art Bindingment auto selected

erator AspectsMaterial source or destination

vides an active material management / inventory systemDefines storage locations, containers, and materialsRecords critical data about material and equipment usageProvides for lot tracking & material genealogy

ables material based phase definitions in batch executionEnables just-In-time material & equipment selection to provide flexible batch manufacturing & real-time production scheduling

ch Material Manager

ch Material Manager

JRP

RUCK UNLOAD

JRP

ADD MATERIAL

stem OverviewEditors Run Time

nual Data Collectionty and Visibility

en, manual data is transposed to electronic form, this data is delayed d vulnerable to errors.ossible, Manual Data collection and/or recording should be automated.

ormation is then instantly available to the entire system for better cision making.

D t I f ti T d S i C i t t Q lit ?

erator Aspects

Many more fields can be capturedegrates manual instructions into automatic batch recipe execution

Provides manual prompts, data acquisition, & SOP’s during running sequence.

Connect to bar code scanner, databases, controllers within instructions Integrates directly into HMI applications Comprehensive Electronic Signatures

ovides automated operator instructions for manual processes Automates the process without the need to automate the equipment Provides secure and reliable instructions to your operators using web

technology Leverage manual SOP’s, documents, video, and/or pictures within instructions

cal manual procedures that can utomated

Manual batch execution and promptsComplex standard operating proceduresPortable hand held applicationsProduct changeover and packaging line changesEquipment startup and shutdown sequencesAbnormal condition handlingCleaning and maintenance procedures

Editors Run Time

ocedural execution Information

oduction information is gathered and stored in an electronic batch cord known as an Event Journal

It’s then transferred to a database using the Event ArchiverProvides users with a batch report to meet production requirements and ample actionable information

toryTalk Batch 12nt Archiver and Reporting NEW

Batch ListingBatch DetailBatch Detail

anding the Batch Data for Premix_01 you get more specific mation about all levels of the unit procedure:

Material UsageForward TrackingBackward TracingBatch ExecutionDuration Comparison

TE: From this view, we see both a bar chart view

batch duration as well as a e of raw data. Notice that early batches 1 & 2 (green lue bars) took longer to cute and the stopped ch 5 (yellow bar) shows a rt duration. This gives the r a good overview of cycle e.

Batch ExceptionsBatch Summary

ndard Reports Available

Plant Floor Operator

Production Management

Executive

• Cycle Time and ThroughputU ti

• Performance and Yields• Capacity

• Forecast Accuracy• Financial Performance

Equipment/Line Focus

Plant Focus

Enterprise Focus

me data, users with different focus…

inuous

atch

crete

Enforce

Specify

Verify

FTB t h h l i th f f t i

ocedure management r the Process industry

Documents

CT531 Batch Management Control - Rockwell … oryTalk Batch 12 pe Release to Production Workflow sily manage your recipe release workflow process by providing a clear ocess workflow