Sustain.Ability. Batch Management Chris Morse, Siva Sundararajan, Frank Offenbacher

2012 Honeywell Users Group Americas
Sustain.Ability.
Batch Management
Chris Morse, Siva Sundararajan, Frank Offenbacher
1
Groundbreaking Technology Shaping Batch Solutions
• New Experion Batch Manager Functionality
–
–
–
–
–
Class based Master Recipes
Recipe Builder
Batch Application Services
New
Server peer responder
Migration from TotalPlant Batch (TPB)
in Orion
• What you will learn if you are:
– Existing batch user
• Business benefits of new batch functionality built into Experion
• Sustain.Ability with migration path from TotalPlant Batch
– User with a new batch or sequential application
• Powerful batch functions built into Experion
• Benefits over server-based batch applications
2
Batch Manufacturing trends
• Tighter Supply Chain Integration
– Planning, Scheduling, MES, and ERP Integration
• Need for Greater Plant and Recipe Flexibility
– Faster new product development & deployment
– More/more complex recipes - move from commodity to specialty products
• Increase Production and Higher Quality Products
– Better use of equipment and automation
• Lower Operating and Lifecycle Costs
– Modular ease of use software for configuration and execution
• Enhanced Process and Product Understanding
– Multi-process, product and plant analysis and optimization
3
Market Pressure to do More with Less
Experion Batch Manager
Moving batch
execution from here
Batch Server
TotalPlant Batch
ACE
or here
C200E
or here
4
C300
to
here
Reduced Hardware & Lifecycle Costs
Batch Manager Business Benefits
• Batch Manager delivers more on-spec product from a batch plant with
lower engineering & support costs
• Sustained operations over server based applications:
– Reduce unplanned downtime
• Reduce cost of rework/disposal of problem batches
• Reduce disruption to production from server problems
• Improved availability with bumpless redundancy
– Improved plant productivity
• Reduced unproductive time between steps
• Typical plant calculates an annual increase in throughput of 3% to 5%
– Improved efficiency through Experion integration
• Standard Experion displays in all user environments
• Reduced recipe maintenance with Class Based Recipes
• Powerful reporting with Procedure Analyst
5
}
New
in Orion
Reducing Lifecycle Costs
Server Based
Lifecycle $
Operability
Special skills
Batch Manager
Microsoft Alignment
Management of Recipes
Lifecycle $
Operability
Single Operator Environment
Special Skills
Single Engineer Environment
Management of Recipes
Class Based Recipes
Routine Change
Routine Change
Single point maintenance
Single Point of Failure
6
Single Point of Failure
Bumpless Redundancy
Reduced Lifecycle Costs through Integrated Technology
Sustaining Knowledge -Master Recipes
Recipe 1
Mixer 1
Recipe 2
Mixer 1
Recipe 3
Mixer 1
Recipe n
Mixer 1
Recipe 1
Fermenter 1
Recipe 2
Fermenter 1
Recipe 3
Fermenter 1
Recipe n
Fermenter 1
7
Sustaining Knowledge -Master Recipes
Recipe 1
Mixer 1
Recipe 2
Mixer 1
Recipe 3
Mixer 1
Recipe n
Mixer 1
Recipe 1 Recipe 1
Mixer 2
Milk
Homogenise
Homogenise
M1
M2
Recipe 1
Fermenter 1
Recipe 2
Fermenter 1
Recipe 3
Fermenter 1
Recipe n
Fermenter 1
Recipe n Recipe n
Mixer 1
Recipe 1
Fermenter 1
Recipe 2
Fermenter 1
Recipe 3
Fermenter 1
F1
F2
Class Based Recipes
8
Recipe 2 Recipe 2
Mixer 2
Recipe 3 Recipe 3
Mixer 21
Reducing Lifecycle Costs with Master Recipes
Recipe n
Fermenter 1
Business Integration - Batch Application Services
Master Recipe: GR1102
Batch ID: TD12345
Batch Size: 75%
Initiator: 1.3 Kg
Initiator: 1.9 Kg
Unit Mixer: M1
MES/ERP:
Master Recipe: GR1102
Batch ID: TD12345
Batch Size: 75%
Initiator: 1.9 Kg
Unit Mixer: M1
Experion
Server
MES
C300
9
C200E
New
in Orion
Improved Production Efficiency with ERP/MES Integration
Control Builder + Recipe Builder – different roles
Control Engineer
Formulator
New
In Orion
• Segregates Recipe Building role from Control Building role
• Reduce maintenance time & avoid errors
• RCMs & Master Recipes only built assigned & loaded in Recipe Builder
• Control Builder remains tool to do everything
10
More efficient Recipe Management through Tool Segregation
Lifecycle Sustainability - Migration
• Legacy Batch Products can be migrated to EBM
TotalPlant Batch
– TotalPlant Batch (TPB)
– Batch Supervisor
– BMS
• Retention of HPM using server peer responder
• Automated Recipe Migration TPB > Batch Manager
– Equipment Model
– Recipes
• Equivalent License Entitlement for TPB via SE&SP
• Specialist resources for migration assessment
11
Experion Batch Manager
Experion TPB C200 to EBM Migration
S88 Procedure/Unit
Procedure/Operation
Process
Server
C200(R)
TPB
Servers
C200(R)
Experion
Stations
C200E (R)
S88 Procedure/Unit
Procedure/Operation
S88 Phases
12
TPB Migration to EBM C300 HPM Retained
GUS
EST
S88 Procedure/Unit
Procedure/Operation
ESVT
Batch
Controller
TPB
APP
Warm
Standby
C300(R)
LCN
NIM (R)
ENIM (R)
LCN tag.parameter
read/write
HM
EHPM (R)
HPM (R)
S88 Phase level
PMCL
S88 Procedure/Unit
Procedure/Operation
LCN tag.parameter read/write
LCN tag.parameter read/write
13
Lifecycle Sustainability through Continuous Evolution
Plant
Expansion
EBM Summary
Experion Batch Manager
14
Other Batch Products
Your
Business Benefit
Reliable, deterministic Batch
Execution in the controller
Batch Execution at a server
Production reliability assured
by full redundancy
Production depends on warm
restart or high availability
server platform
Fast, deterministic transitions
between procedural elements
for efficient batch cycle times
Longer transition times
extending batch cycle times
Batch out of the box
configured in familiar builder
for engineering & operational
efficiency
Additional package involving
training & support
No production interruptions online modification for all
batch functions
Shutdown required for
equipment & phase
configuration
Easy system modifications
without interruption to
production
Distributed batch execution in
any controller
Batch execution on a single
server
System scalability up and
down
Improved production reliability
Improved production reliability
Increased plant throughput
Reduced project & lifecycle
costs
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