1. 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

2. 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

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

4. 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

5. …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

6. 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

7. 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

8. 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

9. 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

10. 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

11. - 3 - Flow Analysis Method
J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna
31/12/2018

12. 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

13. 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

14. 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

15. 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

16. 3. Activate or Sequence Paths to Perform Process1
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

17. 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

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

19. 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

20. 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

21. 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

22. - 5 -
Practical use
J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna
31/12/2018

23. 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

24. 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

25. 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

26. 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

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