Overview of Batch Process - gongkongfs.gongkong.com/files/technicalData/201008/2010082020482900003.pdf · Overview of Batch Process ... Functional Specification Design Specifications

ARC Forum 2010, HyderabadOverview of Batch Process

TR Ravishankar, Vice President, LBU Manager - OCS India & REC Asia Manager /

Madhav Kalia, Vice President, Regional Marketing Unit, BU OCS Asia Pacific, July 16, 2010

Introduction, Session Agenda

Types of manufacturing Processes

Challenges of batch Process

Beyond the Standards

Process Types

Discrete manufacturing

Output: finite quantities of parts

Continuous processes

The output appears in a continuous flow

Batch process

“A process that leads to the production of finite quantities of material by subjecting quantities of input materials to an ordered set of processing activities over a finite period”

Batch means both the material made by and during the process, and "the production of a batch”

Production challenges

Assure product quality and consistency

Manual and automatic equipment coordination

Equipment utilization required at the highest level

Scheduling of batches

Process equipment visualization

Formulation management

Ability to run different recipes on different equipment concurrently

Ability to deviate from the standard methods of operation in wake of

process problems or faults but keep the equipment and plant running

Fast product changeovers

Scalable batch production

Authentic batch reports

Meet Regulatory Requirements(FDA Pat 11)

Business Drivers for a typical Batch plant Business consolidation creates a demand for capturing and documenting knowledge

and expertise

Manpower reductions have created gaps in resources

Too many different styles and approaches to production

Pressure for the reduction of operations and maintenance costs

Reduce capital costs – reduce project costs

Product life cycles are shorter

Time to market can be a “life or death” issue for a new product

Reusing previous best practices has proven to be a way to create new products

Managing a variety of products gets more and more complex

There is a lot of competition for production capacity

Competition between plants with similar capabilities

Inside the corporation

Outside the corporation (e.g., Contract manufacturing)

You must become more flexible and responsive to the marketplace

Create production units that can handle scaleable batch sizes

Customers for your products are demanding Quality and repeatability

What Problems Did Customers Face?

• Code was implemented in Automation systems and separate custom

MIS systems had to be developed for tracking the material and the

overall batch records.

I understand the need to collect data from the controllers, but… … What data needs to be collected? … When should it be collected? …. Do you have the required data in the controller? … Where is it located? … Is there a standard format to the data? … What happens when there are changes made to the recipes….

I am a control guy…not an IT guy

The Production of a Batch

(Actual = Control) Recipe

Noodle Meal for 6 persons

Recipe

Noodle Meal for 8 persons

=

Ingredients

+

Processing

Steps

Product Description

Recipe

May include

Unit / equipment types

To be used

Independent on

Location = Site / Plant

Independent on

Certain unit / equipment attributes

=

Way of heating (electrical or gas)

S-88: Making Order Out Of Chaos

ISA‟s S-88 standard for batch processes gives us a standardized set of

terminology and methods

A common language for the design, operation and and supervision of batching

systems

The terms:

Physical Model: the „pots and pans‟

Procedure Model: the sequence of operations

Activity Model: monitoring availability and allocation of equipment, manual

activities etc.

Separates the recipe from the equipment

Move a recipe from system to system, plant to plant

Change sequences without changing controller programs

../../../Local%20Settings/Temp/C.Lotus.Notes.Data/S88_Rockwell.ppt

International Standard IEC 61512 / ISA S88

S88 defines

A philosophy

A common way of thinking

Good practices for batch manufacturing plants

Design

Operation

Models and terminology

Improve control of batch manufacturing plants

Independent on the degree of automation

Models & Standards in Manufacturing

Level 4

IEC 61131

Fieldbus

ISA 88

(IEC 61512)

OPC

ISA 95

(IEC

62264)

Batch

Control

Discrete

Control

Continuous

Control

Levels

2,1,0

Equipment Control

Intelligent Devices

Equipment Control

Intelligent DevicesAutomation

ERP

MES

Manufacturing

Operations & ControlDispatching Production, Detailed Production

Scheduling, Reliability Assurance, ...

Level 3

Adapted from: ISA-95.00.01-2000

Business Planning & LogisticsPlant Production Scheduling,

Operational Management, etc

AND – the XML Standards

BatchML

BatchML is an XML implementation of the ANSI/ISA 88 family of

standards (ISA-88), known internationally as IEC 61512. BatchML

consists of a set of XML schemas written using the World Wide

Web Consortium's XML Schema language (XSD) that implement

the models and terminology in the ISA-88 standard.

B2MML

B2MML is an XML implementation of the ANSI/ISA 95 family of

standards (ISA-95), known internationally as IEC/ISO 62264.

B2MML consists of a set of XML schemas written using the World

Wide Web Consortium's XML Schema language (XSD) that

implement the data models in the ISA-95 standard.

See WWW.WBF.ORG for more info

http://www.wbf.org/

GAMP 4.0 Figure 6.2

Verifies

Verifies

Verifies

System Build

Functional

Specification

Design

Specifications

OQ

IQ

User Requirements

SpecificationPQ

Project Management in Life Science

Project Planning, Execution & Validation – follow GAMP4/GAMP5

Different ways of running a batch manufacturing plant….

Manual

Semi - Automatic

Fully Automatic

© ABB Group July 26, 2010 | Slide 15

Batch Solutions

A Batch Process could be implemented in several forms

depending on the Process Complexity & Requirement

Specifications

COMPLEX

INTERMEDIATE

SIMPLE

A Simple Batch

A Complex Batch

An Intermediate Batch

Manual mode of operation ….

Implications …..

• High level of dependency on man-power

• Low level of efficiency of operations (computers are better at multitasking)

• Requires physical travel by manpower to each equipment for its operation

• Batch quality and consistency is highly dependent on the individual‟s skill

• Product changeovers take a lot of time

• Field problems take lots of time to resolve

• Lots of manpower time is utilized in preparation of manual batch reports

• Incomplete & erroneous batch reports

• Possibility of manipulation of batch reports to hide operational lapses

• Manual feeding of batch data to create an overall picture of material consumptions

Semi-Automatic mode of operation ….

Implications …..

• Lots of interconnection wiring between local control panels is required

• Construction of field control panels becomes especially complex in case of

plants handling hazardous materials e.g. purged panels or flame proof

panels

•Trouble shooting of such panels becomes cumbersome and requires plant

shutdown as panels have to be de-energized especially in hazardous areas

• Lots of manpower time is utilized in preparation of manual batch reports

• Incomplete batch reports

• Possibility of manipulation of batch reports to hide operational lapses

• Manual feeding of batch data required to create an overall picture of

material consumptions

A Simple Batch Simple Batch :

One Product is prepared as per a defined set of operations (

% Material addition Mixing Filling etc.)

This operation sequence is same always & do not change in

normal circumstances.


Pasteurized

MilkStrawberry

Flavour

Pasteurized

Milk Silo

Add 10%

Flavour

Add 90% Past.

Milk

Strawberry

Flavoured

Milk

PRODUCTS

Mixing Mixing

Mango

Flavoured

Milk

Mango

Flavour

Add 10%

Flavour

A Simple Batch-A Simple Example

Configure SFC‟s with unique

batch operations

Intermediate Batch

Batch ( Intermediate):

On Days „x‟, „x+1‟, „x+2‟: Product -A is prepared with one

set of instructions i.e.(01) in an Equipment.

On Day „x+3‟: Product -B is prepared with a new set of

instructions i.e.(02) in the same Equipment.

On Day „x+4‟: Product A is required again :

The saved Instructions Set (01) now will be recalled.

Small Recipe changes made EASY

- Just select the pre-configured Recipes & Start


Meet FDA norms

Advantages of automatic mode …..

Implications …..

• Reduced dependency on manpower

• Highest level of efficiency as no equipment is kept idle and many

operations are run concurrently

• Almost no physical travel to the equipment is required or even to any

control panel as the equipment are controlled remotely by the control

system

• Highest level of safety of equipment and manpower

• Batch manufacturing becomes highly consistent

• Very fast product changeover…. a matter of a few mouse clicks

• Very pinpointed field problems reporting due to high level of field

instrumentation

•Extensive and secure reporting

•Comprehensive material usage reporting

Advantages of automatic mode …..

Implications …..

• No manpower time required for batch data collection

• System generated batch reports eliminate any possibility of data

manipulation

• Batch data is collected centrally and can be integrated in plant‟s

main database

An Intermediate Batch Solution

MS Access Database

(Simple Recipes stored)

Multiple Recipes with a

different sequence of Actions/

operations stored inside the

Database

Recipes Validated &

downloaded in Controller

Individual Control Phases

choose/ select the recipe to be

used


Compact 800, from ABB for - Batch Implementation

Recipe will reside inside the Controller

Sequential Flow Charts (SFCs) builds Recipes and

the process flow

ISA88 Standards

AC800M with Compact HMI

Batch Implemented for Fermenter, Germinator, Tank farms


A brief overview : Fermenter Recipe

Valve Test

Pressure Test

CIP

Empty Vessel

Sterilization

Media Sterilization

Alkali Sterilization

Fermentation

Complex Batch

Multiple products/recipes

Online Changes to recipes

Equipment sharing (arbitration): Equipment Status i.e.

Avaiable/ Busy/ Reserved )

Automatic Scheduling

Multiple sequences

Multiple controllers

Multiple sites

Plan & schedule based on market demand on real time

basis

Automatically Track & Trace,meet FDA norms


Comprehensive batch automation solution for:

Configuring recipes and

procedures

Configuring batch equipment

Scheduling, monitoring and

controlling batches and

campaigns

Automatic arbitration of

resources between batches at

runtime

Organization of batch

historical information

ABB‟s System800xA Batch Management

Integration with System Operations

Integrated operations improves

operational efficiency and reduces

total cost of ownership.

Common configuration management utilities for Batch Management and 800xA System

Single equipment model used by Batch Management and 800xA System features

Common alarm & event management for entire 800xA System

Integrated security access control for Batch Management and 800xA System features

Seamless navigation between Batch Management and 800xA System process displays

Flexible Recipe Management

Reusable recipe building blocks follow S88 batch control standard

Exception procedures provide recipe-driven error handling capability

Runtime display of control recipes provides operator current status information

Supports on-line changes to control recipe without suspending the batch

Improves production yields,

minimizes scrap, and improves

overall production profitability.

Production Management

Schedule control recipes based on

master recipes and batch-specific

formulation data

Supports multiple execution of

batches within a campaign

Select equipment at schedule time

or dynamically at run-time

View batch status, parameters,

history options and messages

Easily navigate procedure

hierarchy of all active batches

One-button duplicate featureSimple utilities for Recipe,

Resource, and Production

Management

provide full functionality.

Agility

Ability to adapt and make real time decision

Robust and real-time integration between production and business

Remain profitable in this continually changing market requirements

ABB’s Solution

Work Flow Manager (WFM )

Enterprise Connectivity Solution (ECS)


Moving Beyond “Batch”…

Work Flow Manager (WFM) - Dynamic Batch Concept

In typical “Batch” systems modification in the recipe means creating a new master recipe in the “Batch” system.

With WFM‟s dynamic Batch concept only “one” Generic Master Recipe is defined. – Master Workflow

All the needed control recipes are dynamically created on the fly based on the Production Order from SAP PP-PI (Header, Process instructions, process characteristics)

For example : A Dispenser having only 1 master recipe which can handle any product variation.

Any new version release (substitute material, process timings etc.) of the recipe, nothing needs to be modified in WFM / DCS system. Existing master recipe will be able to handle all the variations.

Elimination of errors in creating a new “manual” master recipe every time with release of new products / product versions in a traditional “Batch” system.



WFM - Optimization of Batch Cycle times

by optimizing usage of shared intermediate equipments

In a typically “Batch” system for material dosing to the intermediate shared storage equipments, the starting time / points of these operations are fixed.

Using WFM the material dosing operations can be decoupled from the main recipe and runs as a central optimization service across all recipes.

The shared equipments (weigh hoppers, pigging lines, batching tanks etc.) are modelled as constraints in this optimization.

All the connections for “From” and “To” equipments i.e. for e.g. which Tank can reach which Batching tank or Silo can reach which Weigh Hopper / Charge Hopper etc. can be modeled as constraints in this optimization.

Depending on the progress of different batches and the need of materials as per the process it optimizes the usage of these shared equipments to increase the total throughput of the plant.



ECS’s reliable and robust SAP R/3 Integration

Download Production Order from SAP R/3

Entire production process is running based on the parameters provided by the SAP R/3 control recipe

Standardized, SAP certified and ISA-95 based connectivity provided a seamless on-line integration with the SAP R/3 system.

All the material consumption, phase confirmations, Goods receipt etc. are online sent to SAP as and when the Batch progresses in Production.

Real-time view of latest inventory / stock inside SAP R/3 leads to better planning.



Optimization of IT / Business-Integration Enterprise Connectivity Solution (ECS)

Enterprise Connectivity

ECS Tools

ECS Core

ConfigurationProcess

Definition

Communication Data

ABB

Controls

Devices ABB Historian

Database

Connector

SAP

Connector

Web

Service

Web Services

Connector

IBM ConnectorAny

RDMS

Database

3rd party

Historians

3rd party

Controls

ABB CPM

Produktionsplanung

Produktionsverfolgung

Qualitäts-Management


The ECS Connectors are ready-to-use enterprise services,

Allowing connectivity to a wide range of packaged applications SAP Connector (certified by SAP)

Integrates to any SAP R/3 system through SAP‟s preferred way using BAPI (Business Application

Programmers Interface) or RFC (Remote Function Call) (SAP-Plug-In, SAP-Server Plug-In, SAP IDOC

Plug-In)

Database Connector

Pre-built component connecting with any RDBMS Database running on any platform (ODBC, OLEDB,

MSSQL Server, Oracle)

Batch Connector

Integrates 800xA Batch enabling supervision of batches as provision of master data, batch generation

and monitoring

SSA ERP System Connector

Integrates any ERP system from SSA Global including BAAN supporting the SSA OpenWorldX concept

Web Services Connector

For enhanced SOA applications

More Plug-In´s and Integration opportunuities:

XML-Plug-In, IBM WebSphere MQ Plug-In, IBM Maximo Plug-In, Send Email Plug-In, File-Watcher

Plug-In, Chat-Integration (xMPP Chat server), Open API License (custom developed .Net libraries),

Generic OPC Integration, 800xA Integration


Information available at the Operator Workplace



“ABB's cpmPlus Enterprise Connectivity provides customers

with one of the only productized ERP integration platforms

on the market today. It drives out much of the complexity

and the customization associated with ERP integration,

while providing the all important context that is required

with the production and automation data.

Doing large customized ERP integration projects is a waste

of money. In the current economic environment, end users

that want to cut costs need a solution that provides shorter

order to cash cycles and lower cost of ownership. In

ARC‟s view, ECS provides a cost effective solution that

won‟t take forever to configure and is sustainable.”

Allen Avery – ARC January 2009

Graphical Business Workflow – Modeled with action blocks combined to each other

with logical relations.Business Workflow

ISA95/S88 compliant

SFC - IEC 1131-3

Structure elements

Loops, Actions blocks

Relations - and/or

Transitions – start/end

Action types

Generate Top / Sub Workflow

Generate 800xA Batch recipe

Data Base transaction

ECS (SAP) transaction

Material transaction

LIMS transaction

OPC connect

Customized functions

Action blocks contains

Parameters

Calculations

Process data and signals

Events

Material, Equipment

Optimization of business and production processes Production & Workflow Manager (WFM)

Manages the execution of work orders, recording of production and equipment used

Supports flexible routings including parallel operations, splits, combines

Can have simple rules to enable downstream operations (quantity made, %

complete)

Schedule control recipes based on master recipes and batch-specific formulation

data (800xA Batch Create / Upload module)

Enables automatic Batch-Logging, Tracking, Electronic-Batch-Records, Audit-Trail,

FDA 21CFR Part 11 Compliance

Batch-Status, Batch-Verification, Parameter-Changes

Recording and Reporting of Performance-Indicators (KPI, OEE´s)

Electronic Operator Instructions, Job-Management

Process visualization and monitoring, Work-in-Progress

Material- und Equipment Management, LIMS-Integration…

Optimization of business and production processes Production & Workflow Manager (WFM)

Introduction

Asian Paints:

India‟s largest paint company

Ranked among top ten decorative coatings company in the world

Turnover : INR 66.80 billion

6th Decorative Paint Plant at Rohtak

Capacity:

400 million litres of paint every year.

Ist Phase production capacity: 150 million litres of paint

Products:

Royale, PE, Apex, Ace, TE ( Tractor Emulsion), Primer & Ultima

Pack Sizes: 1, 4, 10 & 20 Litres

Project Initiated in July 2008. Completed in record time of 21 Months !!

http://www.asianpaints.com/








Challenges to provide solution

A system to drive the whole production process.

Optimize the throughput of the plant

No (minimal) waiting time during the production.

Selection of the right equipment for production

Doing everything automatic without additional scheduling and planning

Getting the SAP process orders / recipes via ECS and create “Master workflows” and “Control workflows” accordingly.

Execution of the “Control workflows” and driving the OPC communication to 800xA System or 3rd party DCS / PLC systems.

Integration of any process measurements & maintenance data to SAP

Easily configurable report engine. Reports can be developed very easily using Microsoft Excel®. And viewed using thin client.


Proposed Solution Components

ABB’s cpmPlus WFM (Workflow Manager) for MES and Batch Functionality requirements.

ABB’s cpmPlus ECS (Enterprise Connectivity Solution) for SAP R/3 integration.

ABB’s cpmPlus Smart Client for Data Visualization from various sources i.e. process data from 800xA DCS system, batch data and reports from WFM system, data from SAP R/3 etc.

ABB’s System 800xA for Execution and Control of Phases

Detailed Functional Specification

• Detailed MES requirement mapping with

SAP functionality

• Making the decision up front where the

functionality resides (SAP or MES)

Single Master Recipe – Product independent :

4 Generic master recipes developed for the wide range of products for :

1) TSD

2) Mixer

3) Packing

4) Polymer

Resource Optimization:

Optimized use of various Shared resources – Minimizing the block time &

Increased lifespan ( Eg. – Pig usage in pigging lines)

Easily Configurable Tables( SQL Server Database)

Material Master,

Unit ( or Equipment) Master,

Unit to Unit relation table ( Equipment connection list)

Parameterized mapping with SAP ( Process Instructions & Characteristics )

Efficient Query Based Controls : SQL / Stored procedures

Asian Paints - Successful Implementation

Documents

Overview of Batch Process - gongkongfs.gongkong.com/files/technicalData/201008/2010082020482900003.pdf · Overview of Batch Process ... Functional Specification Design Specifications