Batch standards and the plant optimisation

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Batch standards and the plant optimisation

• Zofia Verwater - Lukszo
• Technische Universiteit Delft
• Z. Verwater-Lukszo_at_tbm.tudelft.nl

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Four levels of plant optimisation

• Process optimisation
• Plant (site) optimisation
• Enterprise - wide optimisation
• Chain, network, cluster optimisation

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Process optimisation

• ISA - S88.01 - 1995, Batch Control. Models and
  Terminology
• Physical model ? Process cell
• Recipe model
• Control activity model

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S88 - Physical model
S88
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S88 - Process cell

• Process cell
• a logical grouping of equipment that includes
  the equipment required for production of one or
  more batches. It defines the span of control of
  one set of process equipment within an area

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S88 - recipe model
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S88 - Control activity model
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Plant (site) optimisation

• Manufacturing Execution Systems (MES) manage for
  a single site of for one or more areas within a
  site
• materials,
• equipment and
• personnel
• ISA - S88 touches the MES - level
• ISA - S95 addresses the enterprise-control
  integration (plant level)

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Manufacturing Execution Systems ...

• deliver information enabling the optimisation of
  production activities from order launch to
  finished goods
• focus on the value-adding processes, help to
  reduce anufacturing cycle time, improve product
  quality, reduce or eliminate paperwork between
  shifts, reduce lead time, etc.

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MES of particular value to operational management

• Functions of MES include
• resource allocation and status,
• dispatching production units,
• data collection/acquisition,
• quality management,
• maintenance management,
• performance analysis,

• operations/detail scheduling,
• document control,
• labor management,
• process management
• product tracking and genealogy

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ISA S88 S95 scope
ENTERPRISE Level
Business Planning Logistics
Interface addressed in the S95.01 and S95.02
standard
MES Level
Manufacturing Operations Control
Area addressed in the S95.03 standard
CONTROL Level
Batch Control
Discrete Control
Continuous Control
Area addressed in the S88 standard
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S95 the three parts
Part 1 Models and Terminology Part 2 Data
Structures and Attributes Part 3 Models of
Manufacturing Operations
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Framework of S95 Part 1
Business Planning Logistics
Manufacturing Operations Control
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Models in the S95 standard
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Functions detailed in S95 Part 1

• Quality assurance
• Product inventory control
• Product cost accounting
• Product shipping administration
• Maintenance management
• Research, development, and engineering
• Marketing and sales

• Order processing
• Production scheduling
• Production control
• Process support engineering
• Operations control
• Operations planning
• Material and energy control
• Procurement

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Functional Data Flow Model
Order Processing
Product Cost Accounting
Product Shipping Adm.
Production Scheduling
Production Control
Product Inventory Ctrl.
Material and Energy Ctrl.
Quality Assurance
Procurement
Marketing Sales
Maintenance Management
Research Development Engineering
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Object Model - shared information
Business Planning Logistics Information
Product Definition Information (How to make
a product)
Production Capability Information (What
is available)
Production Information (What to make and results)
Manufacturing Operations Control Information
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Enterprise - wide optimisation
The culture change
ERP
SSM
CRM
MES
PPE
New process engineer - not only narrow control
issues
Controls
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Chain, network, cluster optimisation

• How to design a flexible infrastructure between
  the various parts of a chain or a network ?
• How to satisfy the objectives and constraints ?
• frequent changes in the quality of feedstocks
• customer-related quality requirements
• tracing, etc?
• What determines the type and the level of
  integration?
• How to optimize ???????

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If you want ...

• to discuss
• to be informed
• to not miss the bus
• join the user group and the discussion platform
  of the
• Batch Knowledge Centre
• www.batchcentre.tudelft.nl

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