real-time recipe and batch management · 2018. 4. 24. · batch management vs. recipe management...

The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.

The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.

Real-Time Recipe and Batch Management

Confidential Property of AVEVA Group plc.

Kevin Murphy

Basics and Fundamentals

Confidential Property of AVEVA Group plc. |

Confidential Property of Schneider Electric |

“A batch process is one that manufactures a finite quantity of material by subjecting

pre-defined quantities of raw materials to a sequential order of processing actions

using one or more pieces of equipment.”

“Batch processes are neither discrete nor continuous but they may have

characteristics of both. The end product that results from a batch process is called

a batch. Batch processes are discontinuous in nature, but many times include

continuous processing elements.”

Batch Process DefinitionExtracted from ISA 88


• Batch: The material that is being produced or that has been produced by a single

execution of a batch process.

Batch is used as an abstract contraction of the words "the production of a batch."

• Recipe: The necessary set of information that uniquely defines the production

requirements for a specific product.

Recipes can contain the following categories of information: header, Formula,

equipment requirements, Procedure, and other information.

• Formula: A category of recipe information that includes process inputs, process parameters, and

process outputs.

• Procedure: The strategy for carrying out a process.

Fundamental Batch TerminologyExtracted from ISA 88


Batch Process Classification

Single-Stream Multi-Stream

Shared

Equipment

Networked Equipment

Shared

Equipment

Concurrenc

y,

Complexity


Batch Industry VerticalsBatch Processes are mainly used in, but not limited to…

Food and Beverage

• Beverages

• Brewing

• Food processing

• Milk processing

Life Sciences

• Pharmaceuticals

• Biotech

• Nutraceuticals

Specialty Chemicals

• Household chemicals

• Paint production

• Pigments, Ingredients…..

Problem Statement*

The supply chain organizations of today’s manufacturers are

under constant pressure to find opportunities to drive

efficiency, productivity and speed to market ... These needs all

encounter a barrier at the human touch points in the

process of transforming a formula or bill of material into

an executable recipe ……

Process manufacturing companies have spent hundreds of

thousands of man hours on Lean projects and Six-Sigma in

order to improve their manufacturing processes, but

generally have not used the same Lean strategy on their

NPDI processes. … *

“Manufacturing Operations Transformation” need in the New Product Introduction Process

The Premier Automation & Industrial IT Conference

*Source: MESA International Whitepaper # 49 “Enterprise Recipe Management”

Recipe Management offers an opportunity for “Manufacturing Operations Transformation”

The Premier Automation & Industrial IT Conference

Source: MESA International Whitepaper # 49 “Enterprise Recipe Management”

Batch Management VS Recipe Execution



Batch Management vs. Recipe Management & ExecutionSystems are traditionally composed of two subparts

Recipe

Creation / Configuration

Recipe

Execution

• One assuring the creation and configuration of the recipes, and;

• The other assuring the execution of the recipes, i.e., driving the equipment to make a product.


Batch Management vs. Recipe Management & ExecutionA Batch Management System adds “Process MES” functionality – i.e.

Batch Management

Batch Scheduling

Equipment Allocation

Equipment Arbitration

Recipe

Creation / Configuration

Recipe

Execution

• Managing a list of orders (here: batches) to be executed now and in future,

• Managing the ability to understand how many times a recipe needs to run to fulfill an order,

• Managing the execution of multiple recipes at the same time using the same equipment

Solution Scope Overview



Overview of our offerings for the Process Industry…and process oriented manufacturing operations

Recipe Execution Capabilities

Fu

nctio

nal co

mp

lete

ness

Home Grown & Proprietary “Recipe” Management

InBatch (Batch mgmt.)

InTouch

Recipe Manager

Batch Management

Recipe Manager Plus,

Standard Edition

Recipe Manager Plus,

Professional Edition


Solution Scope OverviewWhen do you use which product?

Product Solution Scope Functionality

InBatch Concurrent batch execution for

Multi Product, multi streamProduction Environments

Batch Execution Management

(Process MES)

Recipe Manager

Plus Professional Edition

Recipe Management and Execution for

Multi Product, Single Stream Production Processes

Recipe Management and Execution

Recipe Manager

Plus Standard Edition

Machine/Equipment Setup, or

Multi Grade Products

Formula Management and Download

Wonderware Batch and Recipe Management functionality overview

Functionality InTouch

Recipe

Manager

Recipe Manager

Plus Standard

Edition

Recipe Manager

Plus

Professional

Edition

InBatch

Batch Scheduling X

Material Traceability - Product Genealogy X

Redundancy/Store Forward X

FDA 21 CFR Part 11 support X

Recipe (Procedure & Formula) management X X

Electronic Recipe/Batch Records X X X

Versioning/Approval X X X

Server Client Architecture X X X

Formula management X X X X

Recipe Manager Plus Overview

Property of Schneider Electric

Industries seek for increased Operational Efficiency,

consistent Quality and faster Product Innovation

Wonderware Recipe Manager Plus is designed to simplify the processes related to recipe

deployment, optimization and execution in automated manufacturing operations and for

standardization of recipe management across your business


Works with & complements any SCADA, HMI and Control System

Standalone use with any Automation System:

• Connects to any OPC UA Server

• User interface for any device with HTML5 Browser support

• Integration with any HMI with HTML5 Browser control

Integrated with Wonderware System Platform

• Powerful Import Utility


Wonderware Recipe Manager Plus Scaled To Industry Needs

Formula Management and Download

• Generic parameter management and value transfer for any equipment/system

• Serves many production “Recipe” requirements

Wonderware Recipe Manager Plus

Standard Edition

Benefits

• Reduced Machine Setup & Changeover Times

• Consistent production results for process oriented manufacturing

with static procedure


Formula Download (runtime functionality)

Operators can assign a formula,

adjust target values and download the formula with success or error notifications


Wonderware Recipe Manager Plus Scaled To Industry Needs

Adds Recipe Management and Execution

• Recipes are built by combining any Formula with any Procedure

• Serves Batch Processes which require procedural steps

Wonderware Recipe Manager Plus

Professional Edition

Benefits

• Reproducible, consistent Processes and Product Quality

• Reduced Error Rates due to the ability to Manage Procedures,

and Formulas independently


Transitions, Branches, and Loops

Complex Procedures


From None to full ISA 88

Control/Status Interface

compliance

Configurable by the user for

each production capability -

ISA 88 Control / Status Interface Options


Acknowledgement on Exit

Editing Parameter Actuals

Operator notifications

Manual Capabilities


Fill

Label

Pack

Make

MasterData

- Import- Optimize- Approve

Formulas

- Assign- Review- Adjust- Download

Formula Download

System Setup:Define- Equipment- Parameters

Wonderware Recipe Manager Plus Summary

- Create- Optimize- Approve

Procedures & Recipes

- Assign- Review- Adjust- Start

Recipe Execution

InBatch Overview



InBatch software excels at automating the most complex

batch processes or when demanding high flexibility in

recipe creation and modification.

• Empowers Process engineers to rapidly implement recipe

changes or new product recipes

• Maximizes production throughput through it’s multi stream,

multi product batch execution and automation capabilities

• Reduces compliance cost with a comprehensive electronic

batch record, material genealogy, security system event trail

and large set of reports

Wonderware InBatch Strength


InBatch is Flexible Batch Management Software Designed to Model and Automate Batch Processes

• Model-based - Easy recipe creation - Consistent with ISA-88

• Beyond ISA-88 - Connection & Transfer Management

• Recipe import/export/version history using

• Comprehensive production history

‒ Electronic Batch Record and Material genealogy, Web based reports

• Scalable System Architecture – single node to large systems,

integration with Wonderware System Platform

• Efficient Batch supervision and governance including

standard operating procedures for manual operations.

• Security options and support for FDA CFR21 Part11

compliant implementations

• Built-in Hot-Redundancy concepts

• Supports Virtualization with High Availability and Disaster Recovery

Wonderware InBatch Features


Enhancing the ISA-88 Model to enhance flexibility through

recipe modeling

ISA- 88 Modeling

Units

Processes

Process Phases

Process Parameters

Connections

Transfers

Transfer Phases

Transfer Parameters

InBatch Model Extension


Connections and operation/actions of connections (Transfer

phases) following the ISA88 model enable out of the box

capabilities in the Recipe editor and Batch execution logic

Benefits:

• Simpler Recipe modeling with single transfer phases in recipe

with options for automatic or operator connection/target selection

(incl. source/target validation)

• Connections are allocated and used for arbitration in Batch

scheduling to optimize concurrent Batch management

• Full detailed material tracking and reporting out of the box

Increases the ISA88 based graphic recipe modeling

and execution


• InBatch directs and supervises

the batch processing.

• Based on the recipe procedure,

InBatch validates and activates

phases to run after parameter

download

• InBatch also interfaces with the

batch displays enabling

interaction on the batches

running in the system

Batch Execution and Supervision


• Scalable – from Single node to multi (redundant) Server

• Standalone or integrated with Wonderware System Platform

• Control System independent via state interface

and DA servers

• Different levels of security (standalone or integrated)

and electronic signature functionality to fulfill FDA 21 CFR

Part 11 and GMP requirements

• Batch History database and Batch Reports

(MS SQL Server)

• API‘s for advanced or custom recipe management

InBatch Flexible Architecture


InBatch, Batch Management Integrated with your Control

System of Choice

Flexible and powerful

batch management

capabilities

Phases are modeled

within the Control System,

coordinated by InBatch

PHASE 1

PHASE 2

PHASE 3


The InBatch recipe comparison allows analyzing

the differences of two selected recipe version

documents in an interactive drill down report.

InBatch Recipe Comparison report


InBatch provides unmatched capabilities to maximize asset utilization and to reduce

regulatory compliance cost :

• Batch execution management for multi stream, multi product production environments

• Equipment and Connection arbitration, allocation and release

• Control system independent – enabling standardization across the business

• Comprehensive electronic batch record (EBR) and reporting capabilities out of the box

• Complete material genealogy - US and EU standards, IFS,

• Facilitates 21 CFR Part 11 compliance

InBatch provides high flexibility with fast time to value

• Recipe procedure changes without changes to the control system

• Material formulation changes

InBatch & Wonderware System Platform – a unique Batch Manufacturing Solution

InBatch Summary

Thank you

Questions?


real-time recipe and batch management · 2018. 4. 24. · batch management vs. recipe management...

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