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InBatch - Flexible Batch Management Geoff Brown Senior Consultant

Agenda

► InBatch - Flexible Batch Management ▪ Positioning ▪ Integration with Wonderware ▪ Overview of Modules ▪ Process Modelling ▪ Material Management ▪ Recipes ▪ Batch Management ▪ Batch History & Batch Reporting ▪ System Architecture ▪ Summary

What is InBatch?

► InBatch is Flexible Batch Management software designed to model and automate batch processes. ▪ Consistent with S88

(IEC 61512 & ANSI/ISA–88.01 – 1995 Batch Control Part 1: Models and Terminology)

▪ Model-based ▪ Easy recipe creation ▪ “Out-of-the-box” batch simulation ▪ Comprehensive production history ▪ Material genealogy

The InBatch Value Proposition

► InBatch's powerful batch execution engine

(combined with its integration with the other Wonderware components)

significantly reduces the cost and time to implement your batch processes.

Benefits of InBatch Premier

► Reduce the Life-Cycle Engineering Effort ▪ Top down design

▪ Material Unit-to-unit transfers

▪ Re-useable phase block libraries

▪ Sustainable control code

▪ Less dependence on system experts

▪ Built-in batch simulation

Competitive Benefits

► Faster Time-to-Market ▪ Production flexibility

▪ Graphical recipe creation

▪ Performed by non-engineering personnel

▪ Centralized recipe management

▪ Simulate new recipes

▪ Identify scaling and equipment issues

▪ No impact on control code

▪ Eliminate re-validation of the process

Production Flexibility and

Tracking

► Recipe procedure changes

► Material formulation changes

► React to unexpected changes

► Complete material genealogy ▪ International Food Standard (IFS), European

Union (EU)

▪ Bio-terrorism

► Electronic Batch Record ▪ 21 CFR Part 11

Integration with Wonderware

ArchestrA

► InTouch ▪ Configurable Operator Interface which can

show Process and Batch information

► Wonderware Historian ▪ Common MSSQL history database

▪ Comprehensive process reports

► Wonderware Information Server ▪ Current and Historical Reports

► Wonderware Application Server ▪ Complex Phase scripting

▪ Object Library Available

InBatch Premier Extensibility

► ActiveX Controls

► OLE Automation Servers

► Standard, Open History Database

► Connectivity with plant floor

► ERP integration

► Finite scheduling integration

Overview of Modules

► Process Model ▪ Represents a complex batch process in terms

of its processing capability without any reference to hardware.

► Materials Management System ▪ Materials database used to track where

materials are stored and in the construction and execution of recipes.

Overview of Modules

► Recipe Management System ▪ Graphical recipe development system for

creating and sustaining product Master Recipes. Recipes are both equipment and path independent.

► Batch Management System ▪ Manages the process equipment and

orchestrates the execution of the phases within a recipe procedure.

Overview of Modules

► History Database ▪ MSSQL open, relational platform for storing all

batch processing activity including process data, material genealogy, alarms, operator events, comments, etc.

► Reporting System ▪ Integrated reporting system using Wonderware

Information Server.

Overview of Modules

► Security System (option) ▪ 21CFRpart 11 compliant configurable

application and function based security environment

▪ Operating System Security

► InTouch HMI System ▪ Integration with InTouch as the operator

interface including ActiveX objects, and automatic alarm and event storage.

► Connection to Plant ▪ SuiteLink Family of DA and I/O Servers

▪ Wonderware Application Server

A Unit is an equipment entity that holds, processes or packages materials.

Reactor 1 Reactor 2

Hold Tank 1

Hold Tank 2

Bulk Storage 1

Bulk Storage 2

Process Modelling - Define Units

A Connection defines a group of equipment that facilitates the movement of materials from a source unit to a destination unit.

Reactor 1 Reactor 2

Hold Tank 1

Hold Tank 2

Bulk Storage 1

Bulk Storage 2

Process Modelling – Define Connections

A Process Class is a group of units that have the same processing capabilities or perform the same functions.

Bulk Tanks

Reactors

Hold Tanks

Process Modelling – Group Units into Process Classes

Reactor 1 Reactor 2

Hold Tank 1

Hold Tank 2

Bulk Storage 1

Bulk Storage 2

Process Class: Reactors Phases with Parameters: Heat Temp Cool Temp Soak Temp, Time Agitate Speed, Time ManualAdd Quantity

Reactor 1 Reactor 2

Hold Tank 1

Hold Tank 2

Bulk Storage 1

Bulk Storage 2

Process Modelling – Define Phases and Parameters

Reactors

Phase Logic

► Most commonly found implemented in the PLC, DCS or soft PLC.

► Required for each process and connection phase.

► Modular, easy to maintain and re-use.

► Complex “Soft Phases” can be readily implemented within Wonderware Application Server

Phase Logic

Start

Restart

Abort

Reset

Ready

Run

Held

Done

Aborted

Interlocked

Control Inputs

Formula Parameters

Phase Status Phase Control

Interlocks

Control Outputs

Hold

Materials Management

► Provides for the definition and tracking of all batch materials including: ▪ Ingredients, Intermediates, Finished Goods,

and By-products

▪ Material Characteristics

▪ Material Location Assignments

▪ Material Tracking Information

Master Recipe

Recipe

Header

Formula

Equipment

Procedure

Batch Management System -

the Batch Engine

► Schedule Dispatching

► Batch Initialization

► Batch Modes ▪ Automatic, Semi-Automatic, Manual

► Equipment Arbitration ▪ Automatic, Recipe, Manual

► Batch Execution

Batch Execution

► Dynamically transform a Master Recipe (Equipment Independent) into a Control Recipe (Equipment Dependent).

► Orchestrates running of Phases.

► Allocates and Releases Equipment based on: ▪ Is the Equipment Specified in the Train? ▪ Unit Attributes (Capacity, etc.) ▪ Equipment Status (Clean, Dirty, etc.) ▪ Equipment State (Ready, Run, Held, Alarm) ▪ Equipment Availability

Phase

Phase

Phase

Phase

Phase

Equipment

Batch History

Equipment Usage

Materials Used

Materials Produced

Alarms

Operator Changes

Trend Data

Batch Reporting Via WEB

Using WIS

MSSQL

Batch Reporting from MSSQL

► Integrated Reporting System ▪ Implemented using Microsoft Reporting Services as

part of Wonderware Information Server (WIS)

▪ Web reports via Internet Explorer

▪ Real-Time Reporting

• End of Batch Reports, Time Triggers, etc.

• Combines Batch and Continuous Data

▪ Off-Line Reporting

• Historical Data Retrieved via pre-defined reports

▪ Open MSSQL Database for third-party data retrieval and reporting applications

InBatch 9.0 – Reporting

► Report Execution ▪ All pre version 9.0 reports are available

through Reporting Services & WIS

InBatch 9.0 – Reporting -

Examples

InBatch 9.0 – Reporting -

Examples

InBatch 9.0 – Reporting -

Examples

System Architecture –

from Small ..

InBatch Server MSSQL Server & WIS

InTouch Runtime I/O Server

Phase Logic

System Architecture ..

To Large Redundant

Historian

InBatch Servers

Dual Redundant

Pair

Office Clients InTouch/InBatch Runtime Clients

I/O Servers or Application Object

Servers

Phase Logic PLC Network

WIS

PHASE 4

PHASE 5

PHASE 6

Phases modelled within System Platform

Extremely flexible and powerful batch management capabilities

Extremely flexible and powerful platform and plant model

InBatch Server

PHASE 1

PHASE 2

PHASE 3

Phases modelled within Control System

MX communication

System Platform

Device Integration Device

InBatch 9.0 integrated with

System Platform

InBatch Summary

► Complete, integrated robust batch execution system

► Reduces life-cycle costs for batch applications by 40% - 60%

► Provides complete material genealogy

► Provides a comprehensive production history

► Security available that exceeds the most demanding requirements

► Reduces or eliminates custom integration requirements.

► A top-down approach that creates a sustainable solution that responds to change.

Powering intelligent plant decisions in real time.

FDA 21 CFR Part 11

► Electronic Records; Electronic Signatures

► Important Date: August 20th, 1997

► Affects Pharmaceutical & Biotechnology

21CFRpart 11 Major Areas

► Data Integrity ▪ Audit Trail

► Application Security ▪ Application Functionality

• Segment functionality, Auto-Logoff

▪ User Identification • 2 Components Required

▪ Password Management • Password aging, uniqueness, account disabling, minimum

characters

InBatch and 21 CFR Part 11

1995 InBatch Security Manager developed in coordination with customers in the food and pharmaceutical industries.

1996 InBatch 4.0 introduced.

1997 FDA approves 21 CFR Part 11

InBatch was already consistent with the regulation !!!

InBatch 9.0 Security (2009) InBatch 4.0 Security (1996)

InBatch Security Features

► Links activity to electronic Signature ► Provides Audit Trail ► Uses both traditional “Log In” security and

Transactional security ▪ Prevents unauthorized access ▪ Functions can be configured to require up

to 2 electronic signatures

Data Integrity

► Transactional Data – Protect using facilities of MSSQL ▪ Alarms & Events

▪ InBatch Electronic Batch Records

► Continuous Time-stamped data ▪ Wonderware Historian (InSQL) data cannot be

manipulated.

▪ Protect files using Windows Security

Summary

► InBatch Premier Edition ▪ Flexible Batch Management System

▪ Functionally rich

▪ ISA S88 consistent

► 21CFRpart11 Compliant

An InBatch success story British Bakels - Bicester

British Bakels

British Bakels, Bicester, is a leading supplier of baking ingredients. They operate from modern production facilities and offer high service levels to commercial bakeries and other food manufacturers.

Bakels required a system that would simplify the production of hundreds of products whilst providing consistent quality; they chose Wonderware’s InBatch® system which was deployed by Stratos Control Systems Ltd.

Situation, and finding a solution

► Bakels has invested in equipment, tools and training that allow continuous business growth to be achieved.

► To provide smooth and effective operation it was foreseen that the company would need a solution that could flexibly handle the full permutation of recipes and mixes that they needed to process.

► At first consideration was given to a wholly PLC based system but it soon became clear that this was inappropriate to the scale of the problem.

► Bespoke computer solutions were also dismissed as being an unacceptable business risk.

► Stratos proposed a far more powerful and standard solution centred upon Wonderware’s InBatch system, following evaluation this was adopted.

Located on a 5.5 acre site in Bicester, Bakels has invested over £15m in powder blending and wet production, and in warehousing. Production volumes exceed 20,000 tonnes.

InBatch in use

► The use of Wonderware’s InBatch is part of a comprehensive scheme that automates the entire business process.

► The company’s manufacturing plan is held with a Microsoft® Dynamics Axapta MRP system which produces a daily schedule, the end result of which is pallets loaded with the required dry basic ingredients for the day’s production, wet ingredients being pumped automatically.

► The InBatch system takes this schedule information and produces step by step production instructions for operators and automation controllers.

► The process involves weighing, mixing, dosing, blending using a carefully controlled sequence of vessels for melting, dissolving, mixing and cooking.

► The many combinations of ingredients to make Bakels’ products are in this way easily handled without error and with the ability to produce high daily volumes from many differing orders.

► Production at Bakels is arranged in lines, each having flexible operation and capacity to meet differing production demands.

► CIP is built in to the system and is also under full automatic control. .

Dosing, mixing, blending...

InBatch in action...

InBatch in action...

Doing the work...

► The development of the system was done jointly by Bakels’ and Stratos’ engineers, with assistance in the Batch Management consultancy by Wonderware batch specialist Dr Geoff Brown.

► The architecture of the system involves dual server redundancy, Ethernet and wash-down touch screens on the plant itself.

► The system allows both manual and automatic operation and quickly gained operator acceptance following in-house training.

Away from all this activity is Bakels’ product development laboratories, here new recipes are developed both speculatively and also at the request of bakers. Once developed, the production method has to be scaled up to deliver the same characteristics in volume manufacture. Products are formulated to suit each market sector and British Bakels has teams that focus on serving the particular needs of each sector. Bakels’ operation is BRC level “A” accredited (which was the subject of a recent audit by EFSIS that they passed with “flying colours”) and the company has further accreditation as a Halal Food Authority approved supplier and by The Soil Association, as producer of organic products.

Quotable...

Nick Luxemburg, Bakels’ Engineering Manager said, “The system that has been installed provides us with major competitive advantage and the ability to deliver right on schedule”...

“What we have achieved is Consistent Quality”

www.bakels.co.uk

The company has defined expansion plans to establish further lines within the same production area to support planned business growth, the efficiency and flexibility of the batching system contributing to the basis for the business model for this investment.

Success Stories

This case study and many others can be found at...

http://www.wonderware.co.uk/success-stories/

Forthcoming...

► Thin Clients: ▪ 13th January 2010

► InTouch HMI: ▪ 26th January 2010

► InTouch CE (SI’s only): ▪ 10th February 2010

Questions?

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