Quest for the Perfect Batch... A problem... A classic case of pproblems encountered with automation and control without fully understanding the process... Problem description: We had a supply crisis, and increased demand..and we were met with a product taht was failing for poor reliability, high manufacturing costs, adn porduct qulity variances.
Some practical experience with real projects from the real world...
"Last year I was up here speaking for Procter and Gamble...now I can stand here and speak about them!"
by Maurice Wilkins, Chairman of WBF Maurice gave a short update on the Automation Federation......
by Glen Wirth and Marcus Tennant, Rockwell Automation, and Vincent de Gast, Systems Navigator The most common scheduling tools are spreadsheets and batch lists, that are manually updated and do simple calculations, or ERP systems, that tell you what is needed, what is available, and what is required.
by Sandra Vann and Mike Williams, The Dow Chemical Company, and James Destro, Consultant-Siemens. Remember the slide Lynn Craig showed? "Use Money to Make Money?" This is about doing that. How do I ensure that I can get my best return on my tangible asset-- the physical plant.
Exception handling has always been critical to batch operations. Paithankar provided some examples. Conventional approach for exception handling includes a hold hanler and an abort handler of the Unit Phase. Excepton handling is a Major Effort-- 40-50% of Implementation and Testing effort.
Lynn Craig, one of the Process Automation Hall of Fame inductees, and one of ISA's 50 greatest minds in automation, wants us to think about S88 in a different way. What is S88 all about? Basic control sets equipment to a desired state.
Hussein: We needed a paradigm change to eliminate sources of non-compliance within the manufacturing environment. So we came up with a new set of integrated capabilities that both control manufacturing processes and collect detailed information o those processes to enable a platform for continuous improvement programs..
Frede Vinther, NNE Pharmaplan A/S, gave a recap presentation of his presentation at WBF-Europe last fall. He described the similarities and differentiation between batch software packages. Batch has been around forever, long before S88 There are limitations in ISA-88. One batch limited by the extent of a Process Cell.