Batch manufacturer today presents multiple challenges to increase production performance, achieve further product changes & turnover, improve yields while at the same time meeting quality, safety & compliance goals. As companies tackle these challenges, they must look at new and modern approaches to established processes traditionally used in batching applications.

The changing expectations of today’s workforce with the fast-moving pace of technology presents a shift from rigid technology specialist towards operational generalists who demand the easy adoption of tools that have intuitive workflows. A modern batch solution must not only address these challenges with technical capabilities but do so while maintaining the security, integrity, and reliability of the production system.

Customer challenges:

A traditional batch system features one size for all applications. Vendor provided skids are difficult to integrate and control is often duplicated in the batch server, which adds risk to the project schedule and makes it hard to support.

Users in a traditional system have to master several systems and multiple procedural flows in order to keep operations running. Extension to mobile devices is either limited to custom web services or emulated HMI clients with limited functionality. Acknowledgements and workarounds for non-standard conditions are timely to address and cause production delays.

Systems are isolated for security purposes, which makes extraction of data difficult and usually involves gateways, OPC servers, or custom tools. Only proprietary, vendor-specific batching equipment is permitted on the plant network. Servers, workstations, and network switches are limited to a single vendor-provided option, making it difficult to manage IT support and integrate with business ERP systems.

XD SOLUTIONS: MODERN BATCH SOLUTIONS

FactoryTalk® Batch provides efficient, consistent predictable batch processing that supports the reuse of code, recipes, phases, and logic. FactoryTalk Batch combines the ISA-88 standard with proven technology that provides the flexibility ranging from enterprise-wide architectures to complex single-unit applications.

SequenceManager™ provides basic controller-based batch management appropriate for single unit or multiple-independent unit operations. SequenceManager directs programs inside a controller in an ordered sequence for demanding applications.

With SequenceManager, user can deliver fast and reliable execution while reducing infrastructure costs for standalone units. This promotes the delivery of complete skid-based systems that are easy to integrate.

Logix Batch and Sequence Manager (LBSM) is an easily adoptable controller-based batch management appropriate for single-unit or multiple-independent unit operations. LBSM directs application code with a simple configuration from the operator interface. It supports both local and server-client configurations to deliver a consistent user experience.

Numerous styles of reports which commonly used such as: Batch summary, material consumption, traceability, and analysis reports provide reliable and actionable information are provided to present critical production information to help meet key performance goals. Advanced filters and exception-based configurations ensure efficient use of time and resources to streamline the operations.

Benefit

Integration of the batch management system with local skids and controllers utilizing a distributed ISA-88 model results in a more responsive and highly reliable system that is focused on improving operator effectiveness and higher throughput. Systems can easily grow from single unit instances into larger enterprise-wide deployments.

Modern interfaces workflows, and accessibility features enable operators to focus on production needs instead of navigation of the system. Flexible yet secured access to the system eases adoption of a batch system in applications that require manual additions, material tracking, and version control of recipes. Mobile technology enables operators, engineers, and supervisors to quickly address workflow deviations and approvals.

A modern batch system utilises a design for security approach that secures production systems and intellectual property yet helps the plant meet uptime expectations. The system able to simultaneous and make data available for continuous improvement analysis while protecting the integrity of data so that it can be leveraged in regulatory and quality control reporting.