Process Flow Analysis for Flexible, Integrated Automation Jean Vieille Consultant – Industrial Production Control Strasbourg (France) MANUFACTURING IT Bologna, Italy March 01, 2001 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Agenda 1 - Centralized vs Distributed control 2 - Automation Challenge within Production System 3 - Flow Analysis Method 4 - Objects collaboration 5 - Practical use 6 - Conclusion J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Centralized vs Distributed Control - 1 - Centralized vs Distributed Control J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

The Powerful Tyrex… Big brain Centralized design OK for steady / slow changing environment Shortcomings Agility Availability Refer to first computerized systems J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

…vs Stupid Bird Limited intelligence Mostly decentralized design Local decision making at feather level Cope well with unexpected situations Inherently adaptative structure J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Automation Challenge within Production System - 2 - Automation Challenge within Production System J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Automation Challenge Ideal automation Flexibility S88 Manual Operation Capability Flexibility Complexity Ideal automation Manual Operation S88 Traditional Automation Darin Flemming Lou Pillai J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

S88 in Production System Lifecycles Production Schedule S88 : Schedule S88 : Resources Resources Engineering S88 : Equipment Procedural Elements Product Enginnering S88 : Recipe J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

From Goal to Labor Flying chirping Walking Eating Love. Forecasting, Planning And Scheduling Elementary Equipment Control Process Control Definition Equipment Functional Capabilities The Goal: I know What/How To do chirping Eating Love. Walking Flying J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Scheduling hierarchy Business system MES systems SCADA systems ISA S95 Process Control ISA S88 / IEC 61512 OPC IEC 61131 IEC 61499 Equipment Control ISA S50 / IEC 61158 Fieldbus « Intelligent » Device J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

- 3 - Flow Analysis Method J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Concurrent control of actuators Operator Control System Safety System Breakdown J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Material and Energy Flows Energy Sources Energy Sinks A D B E F C Material Sources Material Sinks J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

1. Identify Containers Material Sources Material Sinks A D B E F C J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

2. Identify realistic Paths Material Sources Material Sinks A D B E F C J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

3. Activate or Sequence Paths to Perform Process 1 Material Sources Material Sinks A D B E F C 5 4 3 2 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Several paths simultaneously active Product / lot A Product / lot A Product / lot A Product / lot A Product / lot A J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Objects Collaboration - 4 - Objects Collaboration J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

From Process to Device Control Process Control F2: Fill B F3: Transfer B-> C Function 1: Fill A Device1 Resource 1: Feeding Line D2 R2: Tank A D3 D4 R3: Tank B R4: Transfer Line R5: Tank C D5 D6 R6: Tank D J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Equipment level Control / Failure Measurement Fault Discrepancy Limiting Actuator R2 R1 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Cascading Process Cell Shut-down => Fault F2 => OFF Allocating F1 => Fault R2 => OFF Owning R1 => Fault Adjacent R3 D2 => OFF D1 => Fault J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

- 5 - Practical use J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Limiting actuators – Flow Padlock R1 & R4 un-allocated (or allocated by another Function) R3 R1 A1 Tank R4 R2 A3 A2 Function F1 « Fill tank from R2 » allocates R2 & R3 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Sanitary Status Padlock Upstream Resource Sanitary Status Down-stream Resource Sanitary Status Clean Dirty Product X Product Y Pass Locked J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Equipment Control Project P&IDs Resources Breakdown & Id Generic Objects Definition Process Control Definition Flows & Function Id OPERATION Resources & Functions Design Operational Qualification System Design J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Conclusion Truly decentralized systems are comming All levels well addressed Flow Analysis helps for proper physical modelling Outstanding benefits making OOD practical New thinking processes, may lead to difficulties with Control Engineers Think Pipes rather than Bytes J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018

Information Information available at www.frenchbatchforum.org World Batch Forum WG4 « Flow Analysis » See above link www.wbf.org Powerpoint presentation on request jean-vieille@usa.net J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 31/12/2018