S88 structure used in system configuration IND780batch S88 structure used in system configuration

IND780batch: What is batch?? One of the three types of manufacturing processes: continuous, discrete and batch. According to S88 it is 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 of time using one or more pieces of equipment.” In simple terms: take some fixed amount of raw materials and do something to them to make new material Continuous – involve continuous flow of material through processing equipment (example production of gasoline) … the goal is to product consistent product to matter how long the operation runs (once started they don’t want to stop) Discrete – production of things … specific quantities of parts in a group move from work station to work station, gaining value at each location work is performed In discrete each part maintains its unique identity. (example car manufacturing or our own terminals!)

IND780batch: S88 in simplified terms Standard for batch system design Separates physical equipment from procedural control Creates a common set of terminology and models Makes validation easier Typically includes historical data for tracking Makes reuse of recipe / phase possible across different production facilities

IND780batch: S88 in simplified terms S88 High level view: Equipment + Recipe S88 splits the physical equipment from the logical execution of the process stored in the recipe.

IND780batch: S88 in simplified terms S88 physical model Enterprise (company) Site (plant) Area (section of site) Process Cell (contains all equipment needed to make batches) Unit (conducts one or more major processing activities) Equipment Module (functional group of equipment that can carry out minor processing activities) Control Module (most basic element of physical model, collection of sensors/actuators that act as single control entity) Unit1: Mix Tank1 EM1: Scale 1 EM2: Mixer EM1: Scale 1 CM2: Feed M2 CM1: Feed M1 CM3: Feed M3 CM5: Discharge CM4: Feed M4 Process Cell 1: Mix Line 1 Unit1: Mix Tank1 Unit2: Pasteurizer Site2: Dover Area 1: Material Receiving & Storage Area 2: Mix Tanks Enterprise: Company ABC Enterprise: Company ABC Site1: Iowa City Site2: Dover Area 2: Mix Tanks Process Cell 1: Mix Line 1 Process Cell 2: Mix Line 2 S88 uses a modular approach for its physical model … a system designed to meet S88 standards does not necessarily need to include the three upper areas (enterprise through area) but process cells, units, equipment modules, and controls modules should be Note – in 780Batch we do not define a process cell or unit because the terminal fits the process cell role and each scale fits the unit role. We do have to define the equipment modules / control modules for each scale.

IND780batch: System Architecture Physical Hardware Unit, Equipment Module, and Control Module: Unit (conducts one or more major processing activities) Equipment Module (functional group of equipment that can carry out minor processing activities) Control Module (most basic element of physical model, collection of sensors/actuators that act as single control entity) The terminal provides up to 4 scales and 40/56 digital I/O for EM and CM purposes Multiple unit procedures (and therefore phases) can run concurrently as long as they run on different scales

IND780batch: System Architecture Equipment Module (functional group of equipment that can carry out minor processing activities) For IND780batch there are two major EM types: Scale & Operator Action Scale EM used to weigh materials Operator Action used to inform and accept input from operator Up to four of each can be configured per terminal (4 scale EMs, 4 operator action EMs) Each EM type has its own list of Control Module types

IND780batch: System Architecture Control Module (most basic element of physical model, collection of sensors/actuators that act as single control entity) … control associated I/O for EM Control Module types for Scale EM: Weigh-In Weigh-In Transport Header (multi-material selection) Weigh-In Manual Weigh-Out Weigh-Out Transport Header Weigh-Out Manual Aux1 – Aux4 Used for other I/O based on scale (example: mixer)

IND780batch: System Architecture Control Module (most basic element of physical model, collection of sensors/actuators that act as single control entity) Control Module types for Operator Action EM: Operator Action Controls optional I/O for operator station Input for operator acknowledge Output for alert Output for alarm

IND780batch: System Architecture Physical Hardware Material Paths: In addition to EMs & CMs, IND780batch uses special material delivery control parameters matched to the specific hardware (path) that controls material flow Combination of valves, pumps, motors, piping, etc. to get material from one location to another The combination of the CM and the data from the MP provide the hardware control logic for material delivery 999 material paths are available (this includes both automatic and manual materials) Material paths store specialized parameter data needed for material feed control logic Each path has a set of parameters for that specific set of equipment

IND780batch: System Architecture Master recipes IND780batch stores its master recipes on its compact flash card in one of its standard tables (A3) Max number of master recipes = 1000 The terminal creates control recipes from its master recipes through the creation and execution of an “order” The operator creates an order by selecting a master recipe making any allowed changes in material targets or size of batch – this order is saved in the order table (A7)

IND780batch: System Architecture Control recipes Once an order is created and/or selected to start, IND780batch makes a copy of the master recipe in the control recipe table (A8) Max number of orders = 100 The control recipe is the recipe that is executed and it includes any special operational changes (for example target value changes or batch size rescaling) It also generates the unique batch ID

IND780batch: System Architecture Recipe structure IND780batch recipes can be structured to run as a horizontal or vertical campaign IND780batch recipes consist of unit procedures, horizontal groups and phases Unit procedures can be used to allow simultaneous operations to execute 4 unit procedures can run at the same time Horizontal groups allow multiple phases to be executed as a horizontal “step” Up to 99 phases per recipe 3 1 2 1 2 3

IND780batch: System Architecture Recipe phases Each phase in IND780batch has associated parameter data that is passed to the phase logic for its execution and result data that is passed back from the phase logic to be recorded as part of the batch history table (A9) data Transition from phase to phase is controlled by the mode selection (S88 modes of operation) Auto – as a phase successfully completes the next is automatically started in the order specified Semi-auto – the operator must press “start” to begin the next phase in the order specified Manual – the operator controls the selection of phase and its execution

IND780batch: System Architecture Recipe phase types Unit Procedure group Used to define phases that should run simultaneously vs. sequentially Unit procedure can contain max of 50 phase steps Horizontal group Used to define phase that should run together as a horizontal step Material Transfer – automatic material delivery Manual (material transfer) – manual material delivery

IND780batch: System Architecture Recipe phase types Operator Hold Used to wait for operator acknowledgement, display messages, and collect information from operator Can include graphic image, selection or text box entries, operator “signature” Weight Check Compares weight to provided data Condition Check Allows recipe test a batch variable and make a decision based on its value Communication Used to trigger print or email communications as part of sequence

IND780batch: System Architecture Recipe states / commands The IND780batch follows the S88 model regarding states & commands. Both the recipe and phase execution have status shared data which is reported as part of the batch history and in system information on the operation screens States: idle, running, complete, paused, held, aborted Commands: start, pause, hold, resume, abort Commands can be issued through softkeys or discrete inputs Note: holding / held are created through execution of the operator hold recipe phase