1. S88 structure used in system configuration
IND780batch
S88 structure used in system configuration

2. 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!)

3. 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

4. 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.

5. 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.

6. 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

7. 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

8. 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)

9. 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

10. 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

11. 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)

12. 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

13. 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

14. 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

15. 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

16. 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 communications as part of sequence

17. 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