FIELD INTELLIGENCE Smart Processes, Solutions & Strategies
Batch manufacturers can now throw off old constraints
T
he limitations of traditional batch software are lifting with the introduction of new tech-
nologies, letting process manufactur- ers increase their production velocity and serve a new set of market needs. For decades, the effective use of
batch-management software gener- ally has been confined to slower pro- cesses. Typical applications involved multiple vessels that were part of se- quenced process trains, such as those commonly found in brewing or dairy processing. In those traditional sce- narios, the ISA S88 standard for batch manufacturing satisfied the need for an industry-standard approach. A number of server-based batching solutions adopted the programmatic flexibility at the time, but they also carried limitations that prevented us- ers from applying the standard to all applications in a facility. The solutions also proved too inflexible to meet the changing needs of production. Over time, the software infrastructure that was once a powerful enabler trans- formed into a constraint. Communication lags are one of the main deficiencies in traditional batch applications, which can create a pause between various phases. Due to con- stant interaction in each phase, the equipment and product must tempo- rarily remain in their present condition until the server approves a transition to the next phase. This is problematic, as facilities today are designed around manufacturing velocity and lean tech- niques sensitive to the result of these accumulated wait times. Some system providers tried to solve this challenge by using the
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power of modern controllers to provide faster, more reliable batch control. These controller-level batch systems can apply the same benefits of the traditional server-class systems to new applications. Those include applications that were only achievable through custom methods in the past. Furthermore, advances in control- ler-based programming can leverage firmware locations to control state engines and utilize structured flow chart coding. By shifting away from valuable memory space for complex tasks, this controller-based program- ming can build more reliable plans for OEM process skids.
control functions. By allowing hybrid controller solutions, systems that need fast-transition response can be incor- porated in real time to larger recipes that involve feed and destination ves- sel control. Process equipment can be fully developed and tested at FAT, and then simply integrated into the recipe structure of the batch control system when commissioned. The key benefits of modern batch
systems extend to system interactions and usability needs. Embracing new technology helps improve productiv- ity by providing flexible and intuitive use of the system for both program- mers and operators.
Embracing new technology helps improve productivity by providing flexible and intuitive use of the system for both programmers and operators.
Modern batch systems, though,
need to do more than just leverage the responsiveness of controller- based sequencing. A holistic ap- proach to batch production must include large, complex processes that are spread across several areas with multiple pieces of equipment and controllers. A modern batch system must be able to integrate these ele- ments into the plantwide application for a scalable and flexible architec- ture. This goes beyond control, utiliz- ing the power of servers and report- ing features required in a connected enterprise to integrate higher level MES and ERP systems. Many newer systems engage cloud-based applications for corpo- rate-wide data analytics and quality
Also, extending operator control
and access to the batch system us- ing mobile platforms can improve response times and runtime. This is a particular benefit for solving problems on lines that lie distances apart on large campuses, for example. Ad- ditionally, supervisors and engineers can quickly navigate issues without having to travel to control rooms. The necessary security procedures can be established for immediate access. A modern batch system combines easier deployment with superior results. Taking advantage of faster and more reliable control, intuitive interfaces and a truly flexible, scalable architecture, a modern batch solu- tion is integral to the process control systems of the 21st
century.
Dan UpDyke
Batch Product Manager Rockwell Automation
http://tinyurl.com/zvx3gjg
March 2017
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