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S88 Batchproduction and reporting management |
Batch systems are aimed towards industries having mainly intermittent processes. Industries which are most concerned with such a system are: food, chemical, pharmaceutical and all others requiring control on mixtures or doses necessary (soaking, production of paint...)
These processes consist of components generally in the form of a recipe whose traceability is compulsory, they must assure repeatability, and are subject to quality checks and checks on the fabrication process.
Batch processes often produce different products from the same equipment. This requires a specialised system with the necessary methods and tools for optimum control of the fabrication process. Batch systems rely greatly on methodology and conception tools inspired by standards S88 and IEC61512-1/2. These standards, applied differently in the different systems available, assure command of the Batch processes. They simultaneously involve the bearer of the control engine of the batch sequences, as well as the system reporter of the different information relevant to the progress of the Batch, or to the state of the equipment. The Batch systems bear the tools necessary to model the fabrication process on the basis of strict rules ( eg, rules of physical models and procedural controls, definition of recipes).
Often, the systems used, offer graphics tools, moreover, using the PFC language (Procedural Function Chart).
The implementation of a Batch system is essential for certain industries who have to canvass customers, assuring them that their means of control and life-cycle management of the products measure up to their constraints.
Batch systems have 4 major objectives
To offer great flexibility to their means of production, subject to several functioning rules.
To reduce industrialisation time and research time on new products.
To offer methods and tools guaranteeing a perfect command of the controls (processes and equipment) to be implemented.
To offer the tools which assure complete traceability of each lot produced.
At the very heart of the Batch systems, an execution control engine can be found. This engine relies on the definition of the recipes and the defined models in the system (physical, procedural and activities models). It is in charge of the control and running of each fabrication lot, depending on the rules appointed. Being a sequence-of-execution conductor, it is interfaced with automated systems (eg, PLC, DCS) which translate the running commands to the physical equipment and make aware the different states being part of the Batch activity interface rules. Each fabrication lot is followed through to its execution. The events as a whole, exceptions and the resources involved in the sequence, are the subject of traceability, enabling the reconstruction of all the fabrication conditions (eg, lot file).
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