IND780batch Convert Batch. Internal usage only 2 IND780batch – Convert This presentation details on an advanced feature in IND780batch called Convert

IND780batch

Convert Batch

Internal usage only2

IND780batch – Convert

This presentation details on an advanced feature in IND780batch called Convert Batch. There may be occasions when a batch is completed in an unfinished state, or there may be a batch of base material to be converted into a completed batch. The convert feature allows a batch to be converted into a completely different batch, which eliminates the need to throw out unfinished batches of material. Unfinished batches can be re-run to make a finished product. In general, there are five different methods of converting a batch. Convert Batch can:

- Re-calculate the recipe after too much of a material has been fed.- Repurpose an existing batch by converting it into something different.- Create a new, larger batch from an existing batch.- Use existing materials as part of a new batch.- Adjust material quantities based on lab analysis of an existing

In the following slides you will find examples of how to apply the convert batch feature based on the above five examples.



Example 1:

Customer has a Hand Lotion batching system, and at the end of each batch they perform lab analysis to ensure the batch meets the specifications. After analysis the operator can either discharge the batch or he may be required to add some additional materials for the batch(from the components available)

Discharge Valve

Scale 1

Water Aloe LanolinLavender

Oil



Example 1:- Adjust material quantities based on laboratory analysis of current batch composition

- Recipe 1 is executed and it includes four materials:

- Water = 250 kg

- Aloe = 100 kg

- Lanolin = 100 kg

- Lavender Oil = 50 kg

- After the batch is complete the Lab QC Manager takes a sample of the batch and advises the operator that the following adjustments are required to bring the batch into specification: 1% of Lavender Oil – 1kg 2% of Water – 5kg

- To convert this batch, the operator will need to pull the history data from the terminal and then create a new recipe which reflects the target weights as follows based on the lab analysis:



Example 1:

- To convert this batch, the operator will need to create a new recipe called "Converted Hand Lotion" which reflects the target weights as follows based on the lab analysis:Water = 255 kgAloe = 100 kgLanolin = 100 kgLavender Oil = 51 kg

- The next step is to create a new order using the new recipe we created as our target recipe. Add a new order, enter in the Order ID and Order Description, then select the "Converted Hand Lotion" as the Master Recipe, then press the Convert buton on the bottom of the Add Order Screen to start the Convert Batch Wizard.



Example 1:

- The first dialogue box asks if we want to convert this batch from history. In this case we do because we need the history data from the original batch to compare our target recipe against. Select Yes.



Example 1:

- Step 2 provides us with a list of all the batches stored in history, so we may select which data to convert from. In this example we will select the first one, which contains the history from the original Hand Lotion recipe.



Example 1:

- After we select the file from history to convert, the Convert Wizard compares the actual delivered weigh values with the values in our target recipe and generates new target weights as show on Step 8 tab below.



Example 1:

- The convert Wizard calculated that we need to add an additional 5.2 kg of water and an additional 1.2 kg of Lavender Oil. It calculated these values as follows:

- Note: Only the material transfer steps that have a target weight greater than zero will be executed. A target weight of zero in a material transfer phase will be skipped.

Hand Lotion base recipe

Hand Lotion New Hand Lotion Recipe after lab

analysis

New Hand Lotion Recipe after lab

analysisMaterial Target Weight(kg) Delivered Weight (kg) Target Weight (kg) Target Weight (kg)Water 250 249.8 255.0 5.2Aloe 100 100 100.0 0.0Lanolin 100 100 100.0 0.0Lavender Oil 50 49.8 51.0 1.2Total 500 499.6 506.0



Example 1: Note that when you select OK on the Convert Batch wizard screen, the system will

automatically create a copy of the recipe with all of the conversion changes applied. This recipe can easily be identified in BatchTool, because the system assigns an extra 0 (zero) at the beginning of the recipe name see below for an example.



Example 1:

After the Order is complete, you can download it to the IND780batch terminal. Once it is downloaded the Converted Recipe with the "0" will be deleted from BatchTool. A converted Recipe is only valid for the order with which it is associated, and once executed, will be removed from BatchTool.

Once the order is written to the IND780batch terminal, the operator can execute the converted recipe and produce the corrected batch.



Example 2:

Customer has a paint batching system, and at the end of batching one color of paint they clean the vessel with a small amount of water. Instead of discharging this material from the weigh hopper they want to use this as part of the next batch. This means that we need a way to assign this residual material as one of the materials in the target recipe. This type of convert operation is called "material substitution"



Example 2:

- Royal Splendor paint consists of: Olive Mist paint consists of:

- Red 39% Red 38%

- Yellow 11% Yellow 25%

- Blue 50% Blue 37%

- Each batch of Royal Splendor and Olive Mist will total 1500 kg, including 100 kg of solvent and 900 kg of Base (white). The pigments will total 500 kg. All tolerances are +/- 1%.

- Royal Splendor pigment targets: Olive Mist pigment targets:

- Red 195.0 kg Red 190.0 kg

- Yellow 55.0 kg Yellow 125.0 kg

- Blue 250.0 kg Blue 185.0 kg



Example 2:- The customer ran several batches of Royal Splendor Paint, and uses 25 kg of water to clean

the weigh hopper after the last batch. They are preparing to run a batch of Olive Mist paint and wish to assign the 25kg of water as part of the Solvent component in the Olive Mist recipe. The solvent component consists of 100kg , so we need to reduce the target weight for solvent by 25kg, making the new target weight 75kg. Using the Convert Batch Tool the operator performs the following steps. First lets review the Olive Mist Recipe:



Example 2:

In BatchTool at Orders > New Order, enter an Order ID and Order Description, and select the Master recipe “Olive Mist”.

Next click on the Convert button at the bottom of the Order page.

A dialogue box will help guide the user through the convert feature – see below. The first option is to convert a batch from history. However, in this example we are not converting a recipe from history. Instead we are going to convert our master recipe - Olive Mist paint. Click on No.

A screen like the one shown in Figure 1‑8 will appear. Select the recipe to be converted from the list – in this case, “Olive Mist Paint” is highlighted. Click on OK to continue.



Example 2:

A screen like the one below will appear. Select the recipe to be converted from the list – in this case, “Olive Mist Paint” is highlighted. Click on OK to continue.



Example 2:

The system then asks if the batch was completed. Since the batch has not yet been run, click on No.



Example 2:

The image below shows the next screen, where the target weight for each material can be adjusted. In this example, enter a delivered weight for Solvent of 25 kg, since the scale already contains the 25 kg we wish to use as part of the Solvent material. Set all the other materials to 0 kg, since we have not yet executed this batch and no other materials are present on the scale. When complete press OK



Example 2: The Convert batch function re-calculates the target weight for the recipe based on the data entered

in the previous slide. The new target values appear, as shown below. It is important to review this screen to ensure that the new target weights are correct before moving on.

Now, the converted recipe shows the correct target weight for Solvent, while all other material targets are unchanged. Click on OK to create an order for this converted recipe.



Example 3:

Acme Paint received an order for 10 batches of the Royal Splendor paint. They currently have 12 batches of the Olive Mist in stock and would like to convert this into the Royal Splendor color to fulfill the order.Using the Convert Batch feature, it is easy to convert the Olive Mist paint into Royal Splendor to fulfill the order. This will involve re-scaling the quantities of various components to correspond to the balance of pigments required for Royal Splendor. This process is called Batch Re-Purpose.



Example 3:

- First we need to review the Royal Spendor recipe since this is our target recipe:



Example 3:

- Next, create an order based on this target master recipe. In BatchTool, go to Orders > New Order and enter an Order ID and Order Description. Select the Master recipe “Royal Splendor”.

- Next press the “Convert” button at the bottom of the Order page (Figure 1‑1). This runs the Convert wizard that will help convert the Olive Mist Paint into Royal Splendor Paint.

- In this case we are not converting a batch from history, so select "No".



Example 3:

- Next, we need to select the recipe we want to convert from. So from the list below we need to select the Olive Mist Paint recipe, and press "OK"



Example 3:

- Now we are asked if the batch was completed. In this example we are converting a batch that was completed into a new batch of product. So our batch was completed, so we can select "Yes".



Example 3:

- Next, confirm that all the material in the current batch will be used in the new batch. Click on "Yes", because the new batch is a re-purposing of an existing batch using the same materials, just in different proportions.



Example 3:

- The image below shows that the Convert feature has examined all the materials and determined that proportion of Material 2 –Yellow differs most between recipes. It must be rescaled by the amount shown – 227.27%. The same re-scale percentage will be applied to all the other materials in the batch. Click on "OK".



Example 3:

- The next screen (see below) will show the re-scaled values in the recipe.



Example 3:

- The table below shows how Convert arrived at the new target weight values:

- Convert took the original values for Royal Splendor – the ‘target’ recipe for the conversion – and multiplied them by the largest conversion difference. Here, this was for the Yellow material, calculated at 227.27%. This percentage was derived by taking the Yellow target in Olive Mist and dividing it by the amount of Yellow required by the Royal Splendor recipe:

- The Convert feature calculates the target for each remaining ingredient as follows

Olive MistRoyal

SplendorOlive Mist Converted

to Royal Splendor

MaterialTarget Wt

(kg)Target Wt

(kg) Target Wt (kg)Solvent 100 100 127.3White Base 900 900 1145.5Red 190 195 253.2Yellow 125 55 0Blue 185 250 383.2

125x 100 = 227.27%

55

(Original target value

xConversion factor ) -

Original target value

= Converted target value



Example 3:

- When OK is clicked in the image below, the system automatically creates a copy of the recipe with all the changes applied by Convert Batch. You can identify this recipe in BatchTool because the system assigns an extra 0 (zero) at the beginning of the recipe name.

- This order can now be written to the terminal and executed.



Example 4:

Acme Paints inventory manager found a batch of the white base from which they make their colors, Olive Mist and Royal Splendor. The composition of the ingredients in this batch is listed on the side of each container and he decides to move this batch to the production area to make a batch of Royal Splendor Paint.The container is 1200 kg and is comprised of 150 kg of solvent and 1050kg of white base. This type of Convert function is called Re-Make



Example 4:

- Next, create an order based on this target master recipe. In BatchTool, go to Orders > New Order and enter an Order ID and Order Description. Select the Master recipe “Royal Splendor" as our Target Recipe.

- The Convert wizard asks if a batch is to be converted from history. In this case, click on "Yes", because the history data from the previous batch is available and its actual delivered amount can be used as the starting point for a conversion calculation.



Example 4:

- The delivered weights of the White base batch are shown in the table below:

White Base White Base

Material Target Wt (kg) Delivered Wt (kg)

Solvent 100 151.8

White Base 900 1051.4

Red 0 0

Yellow 0 0

Blue 0 0

Total 1000 1203.2



Example 4:

- Next, from the list of history records select the recipe to be converted. In the list below several batch history files are available. The highlighted recipe in the list is the White Base stock recipe. Then click "OK" to continue.



Example 4:

- The convert function will compare the target recipe selected in step 1 to the source recipe selected from the history screen, and calculate the re-scale amount required based on the largest difference. Click OK, and the next screen will display this value (see below).



Example 4:

- Convert has calculated that the Solvent component exceeds the target amount by 151.8%. It did this by taking the delivered weight for Solvent in the White Base recipe and dividing it by the target weight for Solvent in the Royal Splendor recipe. In this case, the delivered amount of Solvent in the White Base recipe was 151.8 kg, and the Royal Splendor recipe calls for 100 kg.

-

- This amount is greater than the difference between the delivered and target weight for the white pigment, which is only 116.8%. Therefore, the other ingredients are rescaled based on the larger difference. Click on OK to continue.

151.8x 100 = 151.8%

100



Example 4:

- Convert Batch displays the new target weights for each material, based on the re-scale factor of 151.8%.



Example 4:

- To calculate the new target, the Convert wizard takes the target for Royal Splendor – which is what the recipe is to be converted to – and multiplies the target values by the largest conversion difference,151.8%. This factor is then applied to the balance of the materials in the Royal Splendor recipe as follows:

- The same calculation is applied to each material in the Royal Splendor recipe.

- When "OK" is clicked, the system automatically creates a copy of the recipe with all the changes applied by Convert Batch. This recipe can be identified in BatchTool because the system assigns an extra 0 (zero) at the beginning of the recipe name.

- A Convert Batch Order has been created successfully, to convert 1200 kg of White Base Stock into Royal Splendor Paint. This order can now be written to the terminal and executed.

(Original target value

xConversion factor ) -

Original target value

= Converted target value



Example 5:

Acme Glass produces sheet glass using the loss in weight feed system to the right. During production of a batch of sheet glass, the Lime feed gate got jammed and overfed the target by 14.6 kg, for a total delivery of 74.6 kg. The batch terminal was configured to abort the batch if a feed was out of tolerance, so this batch was aborted. The problem with the feed gate has now been corrected but the operator wishes to save the current batch. This process is called Re-Calculate or Linear correction.



Example 5:

- In this example we are going to re-calculate the batch based on the amount of Lime that was overfed. The original target weights for the materials in the batch are shown below:

-

- We already know that the Lime gate got jammed and overfed material by 14.6kg over the target weight of 60kg. The other 2 ingredients added to this batch were delivered as follows:

Silica = 755 kg Soda = 150.2 kg.

- In this example we will use the Convert feature from the terminal itself. In all of the other examples we used BatchTool 780 to covert our recipes. This could also be converted using the BatchTool 780 convert tool.

Target Material -Tol +Tol750.0kg Silica 7.5kg 7.5kg150.0kg Soda 1.5kg 1.5kg60.0kg Lime 0.6kg 0.6kg40.0kg Magnesia 0.4kg 0.4kg



Example 5:

- The batch should now be rescaled based on the delivered lime amount and material amounts reduced by the quantities already added.

- To convert the aborted batch, the operator first creates a new order at the Batch terminal. The steps are as follows:

- In the Order View screen, press the ADD ORDER soft key.



Example 5:

- In the Add Order screen, enter an Order ID and Description, and then select the original master recipe that was running when the batch aborted. In this case, this is a recipe with the ID Glass Batch. The image below shows this information. Next, press the CONVERT BATCH soft key to start the Convert process from the batch terminal.



Example 5:

- The Convert Batch screen (Figure 1‑28) will open, which allows the batch for conversion to be specified. Press the TABLE SEARCH soft key to search for the Batch ID from the history records.



Example 5:

- The BATCH ID SEARCH allows the search to be specified by certain criteria. Alternatively, simply press the SEARCH soft key to view a list of all Batch IDs in the history file.



Example 5:

- The image below shows the list of Batch IDs. In this case, there was only one batch in the history file, which is the batch that aborted when the Lime material was fed out of tolerance. Select this Batch ID and press the soft key to confirm the selection.



Example 5:

- With the batch selected, the system displays the Convert Batch screen again. Verify all information to ensure it is correct before pressing to accept.

- The terminal will recalculate the recipe targets as follows:

- Therefore, the required material additions are:

Lime overage

= (75 kg

) x100%

= 125%60 kg



Example 5:

- Therefore, the required material additions are:

*Note that this value doesn’t change, since it is the basis for the rescaling calculation

- Press OK in the Convert Batch screen. The Order View screen will appear again, and the converted batch can be run to complete the aborted recipe.

Silica = (750 kg x 125%) – 755kg = 182.5 kg

Soda = (150 kg x 125%) – 150kg = 37.5 kg

Lime = (60 kg x 125%) – 75kg = 0 kg*Magnesiu

m= (40 kg x 125%) – 0 = 50 kg



There are several possible combinations of converting a batch, but these examples were provided to allow the ability to preview what the possibilities are to convert a batch.

This is a powerful feature and allows the user to save batches that otherwise might have been thrown out.

Documents

IND780batch Convert Batch. Internal usage only 2 IND780batch – Convert This presentation details on an advanced feature in IND780batch called Convert