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
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
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
© 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.
© ABB Group July 26, 2010 | Slide 18
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
© ABB Group July 26, 2010 | Slide 19
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
© ABB Group July 26, 2010 | Slide 23
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
© ABB Group July 26, 2010 | Slide 24
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
© ABB Group July 26, 2010 | Slide 25
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)
© ABB Group July 26, 2010 | Slide 30
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.
© ABB Group July 26, 2010 | Slide 31
Moving Beyond “Batch”…
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.
© ABB Group July 26, 2010 | Slide 32
Moving Beyond “Batch”…
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.
© ABB Group July 26, 2010 | Slide 33
Moving Beyond “Batch”…
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
Optimization of IT / Business-Integration Enterprise Connectivity Solution (ECS)
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
© ABB Group July 26, 2010 | Slide 36
Information available at the Operator Workplace
Optimization of IT / Business-Integration Enterprise Connectivity Solution (ECS)
Optimization of IT / Business-Integration Enterprise Connectivity Solution (ECS)
“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 !!
© ABB Group July 26, 2010 | Slide 41
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.
© ABB Group July 26, 2010 | Slide 42
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