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The Secret Life of S88 Cause hey, everyone needs a another acronym to remember Russell Czolgosz (Chōl·gŏsh) MTU ChE class of 1999 Lead Automation and Controls.

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Presentation on theme: "The Secret Life of S88 Cause hey, everyone needs a another acronym to remember Russell Czolgosz (Chōl·gŏsh) MTU ChE class of 1999 Lead Automation and Controls."— Presentation transcript:

1 The Secret Life of S88 Cause hey, everyone needs a another acronym to remember Russell Czolgosz (Chōl·gŏsh) MTU ChE class of 1999 Lead Automation and Controls Engineer Dow Corning Corp Modified by DWC 1-11-2010 for CM4120

2 New Employee Training, Midland MIJune 11, 2009The Secret Life of S882 n Background n What is ISA and S88? n Recipe Types n 4-parts of the S88 Model l Physical Model l Process Model l Procedural Control Model l Control Activity Model n Tying it all together Outline

3 New Employee Training, Midland MIJune 11, 2009The Secret Life of S883 Need Predictable Product Quality n Variation in feedstocks n Poor control of manufacturing processes n Human error n Differences between processing locations Overcome High Manufacturing Costs n Low equipment utilization – difficulty in scheduling n Using old processing/control technologies n Labor intensive n High cost of energy n Poor flow of material and information Would Like New Markets/ New Products n Need Agility but have a dedicated system n Rigid design creates long product/process development times Typical Manufacturing Challenges

4 New Employee Training, Midland MIJune 11, 2009The Secret Life of S884 1. Design equipment for a specific process/ product 2. Develop procedures to make that product 3. Implement process control to meet the product requirements and fit the SOP 4. At completion all aspects of the SOP/ product/ equipment/ control are rigid, hard- coded, and fixed This type of implementation: Hinders Process Improvement Prohibits Manufacturing Agility Prevents Asset Optimization The goal of S88 is to prevent these roadblocks. Traditional Process Development

5 New Employee Training, Midland MIJune 11, 2009The Secret Life of S885 n ISA – International Society of Automation n S88 (or ISA 88) Batch Control Standard Currently a 4-part standard l Part 1 Models and Terminology (ANSI/ISA-88.01) l Part 2 Data Structures & Guidelines for Languages (ANSI/ISA-88.00.02) l Part 3 General and Site Recipe Models & Representation (ANSI/ISA-88.00.03) l Part 4 Batch Production Records (ANSI/ISA-88.00.04) l Part 5 is currently in draft n SP88 is the Batch Control Standards Committee ISA S88 is...

6 New Employee Training, Midland MIJune 11, 2009The Secret Life of S886 The Intent of S88: n Promotes modularity and flexibility n Emphasizes good practices for design/ operation n Provides a common concepts, framework, models, and terminology n Improve efficiency/ control of mfg. plants (batch, semi-continuous, and continuous) It is a guideline, NOT a compliance standard

7 New Employee Training, Midland MIJune 11, 2009The Secret Life of S887 S88 – Must be Interpreted! n S88 defines general practices l Written to apply to the entire processing industry l Makes suggestions and provides examples l Does not list requirements n Suggests standardized modular design concepts l Reusable design components l Similar to object-oriented computer programming

8 New Employee Training, Midland MIJune 11, 2009The Secret Life of S888 Benefits of an S88 Solution? 1. Modularity allows for easier replication and better ROI 2. Design concepts make validation easier 3.S88-aware solutions help track product and process data 4.Gathering requirements from customers/ conveying requirements to vendors is easier 5.Provides guidelines on how to recover from abnormal events

9 New Employee Training, Midland MIJune 11, 2009The Secret Life of S889 Spirit of S88 nNot just a standard for software, equipment, or procedures l A new way of thinking – a design philosophy nUnderstanding S88 will help you design better processes and manufacture better products l Isolates equipment from recipes

10 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8810 Improved Batch Processing l Reduced batch cycle time l Increased production rate l Faster changeover l More scheduled recipes l Reduced downtime l Faster process development l Quicker product launches l Reduced raw material loss l Improved batch consistency l Better equipment utilization l Less time to add/modify recipes l Lower engineering cost l Lower data capture cost l Better data availability ThroughputCost

11 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8811 Steps in Applying S88 1. Learn the terminology 2. Break the process down into appropriate components 3. Identify the steps necessary to produce the product 4. Identify recipe parameters 5. Tie the recipe to the procedures 6. Map the procedure to the processing equipment

12 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8812 S88 Recipe Types What we want to make, what equipment we need, and how we want to do it

13 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8813 4 Recipe Types May be transformed into General Recipe Site Recipe May be transformed into Master Recipe May be transformed into Control Recipe Ref. S88.01 Fig.8 – Recipe types 1.General Recipe l Enterprise-wide l Includes product-specific processing information 2.Site Recipe l Specific to a site l Includes site-specific information (language, raw materials, on-site limitations, etc.) 3.Master Recipe l Targeted to a specific cell l Starting w/ a Site Recipe, is adapted to Process Cell-specific equipment 4.Control Recipe l Consists of a Master Recipe plus Batch ID, batch size, etc. l Forever tied to a particular batch and is specific to that batch – permits product tracking

14 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8814 n A recipe holds the data that uniquely identifies the components of a specific product l Ingredients to use l Quantity of ingredients l Equipment requirements l The order in which tasks are performed n Recipes do not contain scheduling or equipment control information Recipe Definition

15 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8815 1. Process Model 2. Physical Model 3. Procedural Control Model 4. Control Activity Model Applying S88 – 4 Models Defined

16 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8816 S88 The Process Model Describes the hierarchical ordering of process functionality needed to produce a batch. Is not equipment specific – very conceptual. Used to develop the recipe procedures section in the General and Site Recipes (high-level recipes).

17 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8817 Process Model Process Stage Process Operation Process Process Action General and Site Recipe procedures will be based on the Process Model Consists of an ordered set of Make PDMS Polymerize Remove Low Boilers Cool Product Prepare Reactor Charge React Add reqd 245 Fluid Add reqd Endblocker Heat to 140 C

18 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8818 S88 The Physical Model The equipment used to perform the process. Defines the hierarchy of the equipment.

19 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8819 Physical Model Enterprise Site Process Cell Unit Area Equipment Module Control Module Process Cell Unit Equipment Module Control Module MTU Houghton Chem Sci Building Consists of all the production and supporting equip necessary to make a batch A major piece of equipment within a process cell that performs a specific task Grouping of equipment & control modules that together perform a minor task Basic discrete and analog control (output) devices PSCC PDMS Reactor Unit Solvent Recovery Unit Agitator Temp Feed Discharge Agitator Controls Outlet valve Temp Controller Subdivision of the corporations PHYSICAL ASSETS organized in a hierarchy of equipment that consists of several integrated levels

20 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8820 An Example Process Cell Mix Discharge and Recirc Pressure Control Temperature Control Material Charging Material Selection M FT TT PT Pump Control Module Equipment Module Unit Process Cell FT

21 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8821 Defining a Unit n Batching cannot occur without units l Batching occurs in units l Units perform one or more major processing activities l A unit is used on only one batch at a time n A Unit runs a recipe l Combine ingredients, or perform a reaction l Adds value to your product or intermediate n Units function independently of each other Control Module Equipment Module Unit Process Cell

22 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8822 Examples of Units: Mix-making batch tank Is a Unit Is Not a Unit Reactor Pump Ingredient storage tank Washing machine Kitchen blender Refrigerator Dishwasher Pasteurizer 4 4 4 4 4 4 4 4 4

23 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8823 Equipment Modules n Equipment modules group devices for performing one or more specific minor processing activities n Equipment modules run portion(s) of a recipe Material Charging Equipment Module FT Control Module Equipment Module Unit Process Cell Mix M

24 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8824 Control Modules n Control modules connect software to the process through sensors and actuators n Act as a single entity from a control standpoint n Carry out Basic Control – they do not contain procedural control Control Module Equipment Module Unit Process Cell Temperature Control TT Material Selection

25 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8825 Physical Model is Collapsible Although a process cell must contain at least one unit: n A control module does not have to be part of an equipment module to be part of a unit n A unit can own control modules directly Control Module Equipment Module Unit Process Cell

26 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8826 S88 The Procedural Control Model Sequence of steps necessary to produce a batch. Defines the sequential control that enables equipment to perform the process task. Used to develop the Recipe Procedures section of the Master Recipe The specific control setpoints, quantities, controller modes, etc. required to make a defined quantity of a certain product

27 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8827 Procedural Control Model Procedure Unit Procedure Operation Phase Defines the process strategy for making a batch within a process cell -A hierarchy of the actions that are performed to complete a batch Defines the actions that are performed on a Unit -Consists of an ordered set of Operations that control the functions of the unit Defines an ordered set of phases that are arranged to perform a particular function within a unit -One or more operations could occur simultaneously Defines a simple action or command to set or change the state of an Equipment Module -Can be subdivided into steps and transitions Add 245 Add Endblocker Prepare Reactor Add Ingredients Heat Polymerize Remove Low Boilers Cool Product Make PDMS

28 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8828 Procedural Control Model Example Make Toothpaste UnitProcedures Operations Phases Procedure Make Paste Prepare Tank Add Water Make GelSwirl Add Ingredients React Add FillersAdd NaF Phases are the workhorses. Other levels simply group, organize, and direct phases. Phases are the workhorses. Other levels simply group, organize, and direct phases.

29 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8829 The Automation Specification: A document that describes how Equipment Modules are related to a Unit and how the Phase(s) control each Equipment Module Control Module Equipment Module Unit Process Cell Area Site Enterprise Phase Operation Unit Procedure Procedure Physical Model Procedural Control Model

30 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8830 S88 Models Tie Together thru Mapping Relates the procedural control model to the physical model to provide the processing described in the process model Involves MAPPING of Procedural Elements into Physical Entities

31 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8831 S88 – Model Relationships + Provides the functionality to carry out a… Ref. S88.01 Fig.7 – Procedural control/equipment mapping to achieve process functionality Process Stage Process Operation Process Provides process functionality to carry out a… Unit(s) Equipment Module(s) Process Cell Unit Procedure Operation(s) Phase(s) Procedure + Combined With a = = = + + Process Action Procedural Control Model Physical ModelProcess Model

32 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8832 Separation of Recipe, Procedures, Equipment/ Basic Control into separate models: n Each component is maintained as an entity n Changes in the Recipe do not necessarily require changes to the Phase Logic n Changes to the Phase Logic do not necessarily require changes to the Recipe n Changes to physical equipment do not necessarily require changes to the other models Separate Models Add Flexibility

33 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8833 Corporate sends a General Recipe to my Site n Convert General Recipe to a Site Recipe then n Convert Site Recipe to a Master Recipe, for each suitable cell, complete with setpoints, timing, quantities, tolerances, etc. When we make a Batch, the Master Recipe gets transformed into a Control Recipe n allocate specific equipment n create a batch identifier n make the product, record all processing parameters n Control Recipe forever tied to that batch of product Summarizing the 1 st Three Models

34 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8834 In our plant, we define: n Physical Model (what Units and Equipment Modules we have and the Basic Control that operates each) n Procedural Control Model (all the Phases that each Equipment Module can be in, what each Phase accomplishes, and the sequence of operations) Mapping the Physical Model onto the Procedural Control Model produces the functionality described in the Process Model Process Model describes what Process Actions will occur in each Phase of the process Summarizing the 1 st Three Models

35 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8835 Original Nestlé Toll House Chocolate Chip Cookies Makes about 5 dozen cookies Ingredients: 2 1/4 cups all-purpose flour 1 teaspoon baking soda 1 teaspoon salt 1 cup (2 sticks) butter, softened 3/4 cup granulated sugar 3/4 cup packed brown sugar 1 teaspoon vanilla extract 2 large eggs 2 cups (12-ounce package) NESTLÉ® TOLL HOUSE® Semi-Sweet Chocolate Morsels 1 cup chopped nuts Directions: PREHEAT oven to 375° F. COMBINE flour, baking soda and salt in small bowl. Beat butter, granulated sugar, brown sugar and vanilla extract in large mixer bowl until creamy. Add eggs one at a time, beating well after each addition. Gradually beat in flour mixture. Stir in morsels and nuts. Drop by rounded tablespoon onto ungreased baking sheets. BAKE for 9 to 11 minutes or until golden brown. Cool on baking sheets for 2 minutes; remove to wire racks to cool completely. O p e r a t i o n s Procedure Batch of Cookies! Formula Inputs Control RecipePhasesRecipe ParametersBatch Size Master Recipe Transition Expression Recipe Header

36 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8836 S88 The Control Activity Model The 4 th Model Cactus Model Shows relationships between control activities Describes flow of information throughout the enterprise

37 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8837 Control Activity Model Production Information Management Recipe Management Production Planning and Scheduling Process Management Unit Supervision Process Control Personnel and Environmental Protection Below this line is outside S88 Scope Process Data Batch and Process Cell Information Batch Progress Batch Schedule Master Recipe Master Recipe Master Recipe Batch Schedule Batch and Unit Information Batch Status Statuses Commands Unit Recipes and Commands Commands

38 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8838 n Permits easy product customization l Color, level of impurities, packaging, viscosity, composition, etc. n Facilitates rapid product change-over n Helps identify suitable assets at different sites n Allows for easy recipe conversion into local languages Remember: S88 is only one element in a system of manufacturing Overall Value of S88

39 New Employee Training, Midland MIJune 11, 2009The Secret Life of S8839 References n Applying S88 Batch Control from a Users Perspective, Jim Parshall and Larry Lamb, ISA, Research Triangle Park, NC, 2000. n ISA S88.01-1995 (R2006) Batch Control Part 1: Models and Terminology, ISA, Research Triangle Park, NC, 2006. n World Batch Foundation, www.wbf.org www.wbf.org n International Society of Automation, www.isa.org www.isa.org


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