T108 Batch Management & Control

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

PUBLIC INFORMATION

T108 – 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

AGITATE

JRP

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

Equipment

Phase

Synchronize with controller to create each phase instance code structure


WeighMixerReactor

System Overview

Editors


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.


Operations aspects(Batch Security)

Application security

User authentication at Logon

Command Authorization security

Full access control to operations

Ensures that personnel are prompted for

signatures when commands are executed.

Parameter and Report deviation authorization

Manual and Automatic Phases

Three Levels of limit values can be secured

Electronic Signatures

Up to three signatures for authorization

Logs intent of each signature

Full names logged in event journal

Available in Batch View and active X’s

Limits and

values displayed

Required Signatures,

* is the last one to sign


2

FactoryTalk Batch 12Recipe and Area Model Security

Recipe procedures encapsulate the best practices in performing your

processing tasks

The value of these recipes often contain your competitive

differentiators

Controlling the unauthorized distribution of this information is

paramount.

Protect your recipes and equipment model

intellectual property by assigning them a

Security Token Identifier

generated by your system

NEW


2

FactoryTalk Batch 12Recipe Release to Production Workflow

Easily manage your recipe release workflow process by providing a clear

process workflow definition and visibility for each recipe

Enforce signoffs prior to releasing the recipe as a “step” or to production

Different signature templates are created and a workflow is configured

Each recipe will log its signoffs

NEW

For compliance with Good

Manufacturing Practices (GMP),

releasing or removing a master

recipe to/from production requires

the consensus of multiple

stakeholders


2

FactoryTalk Batch 12Recipe Versioning

Version control simplifies managing and

tracking recipes

Allows recipe authors to save and

retrieve versions of a recipe

Once a recipe is checked in it can’t be

altered

It can be checked out as a “work in

progress” (WIP) and then checked in

as a new version

As recipe procedures evolve:

Keep track of the genealogy of your procedural files

Recall how a product was manufactured

Carry out experimental procedures and get back to an earlier

version if required

Operation_A

Operation_A 1. New / Save as

2. Save

Operation_A

3. Save

Operation_A~V1

4. Check IN

Operation_A~V2_WIP

5. Check OUT

Operation_A~V3_WIP 7. Check IN

Operation_A~V2

Operation_A~V4_WIP

8. Check OUT

Operation_A~V4

9. Check IN

Operation_A~V3

6. Check OUT

10. Check IN

NEW


Equipment

Phase

Equipment

Module

Control

Module

Editors Run Time

Automated and manual procedural activities


Engineering Aspects (Reusable code and templates)

Display components / Controller codeStandard valves / Standard Motors / Standard Totalizers / Etc.


Engineering Aspects (Reusable code and templates)

Batch Active X components


Equipment

Phase

Equipment

Module

Control

Module

System Overview

Editors Run Time


ERP / MES

API Call

Manual Activities

Scheduling Batches

Automated ActivitiesOperator


For example, A 13,000 liter campaign size is created with a batch size of 5,000 liters.With Allow Single Odd-Sized Batch selected, there will be two batches at 5,000liters and a single (third) batch created with a batch size of 3,000 liters, thus fulfillingthe campaign size specified (2*5,000) + 3,000 = 13,000 liters.

Flexible batch/campaign creation• Add individual batches – you can specify the size of each batch in the campaign.

• Create campaigns with multiple batches – you can automatically generate the campaign of

batches using the quantity/size or a value in between that is applied to all batches in the

campaign.

Scheduling Aspects(Batch campaign)


The enabling technology to build equipment (unit) binding requirements and preferences into procedures.

Decisions can be based on: Preference

Requirement

Use “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)

Smart BindingEquipment auto selected

Use to optimize the selection of production equipment


Operator AspectsFind Material source or destination


Provides an active material management / inventory system

Defines storage locations, containers, and materials

Records critical data about material and equipment usage

Provides for lot tracking & material genealogy

Enables material based phase definitions in batch execution

Enables just-In-time material & equipment selection to provide flexible batch

manufacturing & real-time production scheduling

Used to solve material management requirements

Batch Material Manager


Batch Material Manager

JRP

TRUCK UNLOAD

Raw material receiving / Finished product shippingRaw material usage

JRP

ADD MATERIAL


Equipment

Phase

Equipment

Module

Control

Module

System Overview

Editors Run Time


Manual Data CollectionQuality and Visibility

Often, manual data is transposed to electronic form, this data is delayed

and vulnerable to errors.

If possible, Manual Data collection and/or recording should be automated.

Information is then instantly available to the entire system for better

decision making.

Data Information Trends Summaries … Consistent Quality?


Operator Aspects

Many more fields can be captured

Integrates 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

Provides 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

Use to solve manual SOP requirements

Confirm valves are in correct position

Closed

Open

Open

Closed

Typical manual procedures that can

be automated

• Manual batch execution and

prompts

• Complex standard operating

procedures

• Portable hand held applications

• Product changeover and packaging

line changes

• Equipment startup and shutdown

sequences

• Abnormal condition handling

• Cleaning and maintenance

procedures


Equipment

Phase

Equipment

Module

Control

Module

Editors Run Time

Procedural execution Information


Production information is gathered and stored in an electronic batch

record known as an Event Journal

It’s then transferred to a database using the Event Archiver

Provides users with a batch report to meet production requirements

and ample actionable information

FactoryTalk Batch 12Event Archiver and Reporting

NEW


010 – Batch Listing030 – Batch Detail030 – Batch Detail

Expanding the Batch Data for Premix_01 you get more specific

information about all levels of the unit procedure:

040 – Material Usage050 – Forward Tracking060 – Backward Tracing070 – Batch Execution080 – Duration Comparison

NOTE: From this view, we

can see both a bar chart view

of batch duration as well as a

table of raw data. Notice that

the early batches 1 & 2 (green

& blue bars) took longer to

execute and the stopped

batch 5 (yellow bar) shows a

short duration. This gives the

user a good overview of cycle

time.

090 – Batch Exceptions020 – Batch Summary

Standard Reports Available

Plant Floor Operator

Production Management

Executive

• Cycle Time and Throughput

• Uptime

• Performance and Yields

• Capacity

• Forecast Accuracy

• Financial Performance

Equipment/Line Focus

Plant Focus

Enterprise Focus

Same data, users with different focus…


Continuous

Batch

Discrete

Enforce

Specify

Verify

FTBatch helps you increase the success of your manufacturing process

Procedure management for the Process industry

Documents

T108 Batch Management & Control