WW OPS-01 Consistent and Flexible Batch Execution with Wonderware InBatch

WW OPS-01 Consistent and Flexible

Batch Execution with Wonderware

InBatch

Dirk Kozian

Product Manager

Michael Schwarz

Product Marketing

Dirk Kozian

Product Manager

Michael Schwarz

Product Marketing

What is Wonderware InBatch?

InBatch is control system independent Batch Management Software, designed to effectively Model and Automate Batch Processes

Successfully used, globally for nearly two decades:

• 1000+ installations globally

• Verticals: Pharmaceutical, Life Science, Healthcare, Chemical, Petrochemical, Food & Beverage, Construction materials etc.

• Long term domain expertise in Ecosystem and Employees

• Used with all major PLC brands and Foxboro I/A Series DCS

• Area of continuous Investment and Industry Standard Support

InBatch is control system independent Batch Management Software, designed to effectively Model and Automate Batch Processes

Successfully used, globally for nearly two decades:

• 1000+ installations globally

• Verticals: Pharmaceutical, Life Science, Healthcare, Chemical, Petrochemical, Food & Beverage, Construction materials etc.

• Long term domain expertise in Ecosystem and Employees

• Used with all major PLC brands and Foxboro I/A Series DCS

Wonderware InBatch Strengths

InBatch software excels at automating the simplest to the most complex batch processes or when demanding high flexibility in recipe creation and modification.

• Empowers Process engineers

to rapidly implement recipe changes or new product recipes

• Maximizes production throughput

through its multi-stream, multi-product

batch execution and automation capabilities

• Reduces compliance cost

with a comprehensive electronic batch record, material genealogy, security system event trail and large set of reports

InBatch software excels at automating the simplest to the most complex batch processes or when demanding high flexibility in recipe creation and modification.

• Empowers Process engineers

to rapidly implement recipe changes or new product recipes

• Maximizes production throughput

through its multi-stream, multi-product

batch execution and automation capabilities

• Reduces compliance cost

with a comprehensive electronic batch record, material genealogy, security system event trail and large set of reports

What is Wonderware InBatch?

InBatch is Flexible Batch Management Software Designed to Model and Automate Batch Processes

• Model-based - Easy recipe creation - Consistent with ISA-88

• Beyond ISA-88 - Connection & Transfer Management

• Recipe import/export/version history using

• Comprehensive production history

- Electronic Batch Record and Material genealogy, Web-based reports

• Scalable System Architecture – single node to large systems, integration to Wonderware System Platform

• Efficient Batch supervision and governance including standard operating procedures for manual ops

• Security options and FDA CFR21 Part11 compliance

• Built-in Hot Redundancy concepts

• Supports Virtualization with High Availability and Disaster Recovery InBatch is Flexible Batch Management Software Designed to Model and Automate Batch Processes

• Model-based - Easy recipe creation - Consistent with ISA-88

• Beyond ISA-88 - Connection & Transfer Management

• Recipe import/export/version history using

• Comprehensive production history

- Electronic Batch Record and Material genealogy, Web-based reports

• Scalable System Architecture – single node to large systems, integration to Wonderware System Platform

• Efficient Batch supervision and governance including standard operating procedures for manual ops

• Security options and FDA CFR21 Part11 compliance

• Built-in Hot Redundancy concepts

Flexibility gained by managing the

complexity – Process Model

The Plant contains

• People, Equipment & Materials

The Process Model defines

• Equipment Resources • Capabilities

• Relationships to other Equipment Resources

The Recipe combines

• Header

• Equipment

• Formula

• Procedure

How to get the most out of the “Plant” ?

The Plant contains

• People, Equipment & Materials

The Process Model defines

• Equipment Resources • Capabilities

• Relationships to other Equipment Resources

The Recipe combines

• Header

• Equipment

• Formula

• Procedure

How to get the most out of the “Plant” ?

Batch Management

Recipe Management

Batch Management Systems

are traditionally composed

of two subparts:

One assuring the

creation

and configuration of the

recipes

, and;

The other assuring the

execution of the recipes

,

i.e., driving the equipment

to make a product according

to a production order.

Batch Management Batch Execution

Management

Batch Management Systems

are traditionally composed

of two subparts:

One assuring the

creation

and configuration of the

recipes

, and;

The other assuring the

execution of the recipes

,

i.e., driving the equipment

to make a product according

to a production order.

 InBatch Model Extension ISA- 88 Modeling Units Processes Connections Transfers

Enhancing the ISA-88 Model to enhance

flexibility through recipe modeling

Processes Process Phases Process Parameters Transfers Transfer Phases Transfer Parameters

Increases the ISA88 based graphic

recipe modeling and execution

Connections and Operation/actions of connections (Transfer phases) following the ISA88 model enable out of the box capabilities in the Recipe editor and Batch execution logic

Benefits:

Easier Recipe modeling with single transfer phases in recipe with options for automatic or operator connection/target selection (incl. source/target validation)

Connections are allocated and used for arbitration in

Batch scheduling to optimize concurrent Batch management Full detailed material tracking and reporting out of the box

Connections and Operation/actions of connections (Transfer phases) following the ISA88 model enable out of the box capabilities in the Recipe editor and Batch execution logic

Benefits:

Easier Recipe modeling with single transfer phases in recipe with options for automatic or operator connection/target selection (incl. source/target validation)

Connections are allocated and used for arbitration in

Batch scheduling to optimize concurrent Batch management Full detailed material tracking and reporting out of the box

Describing the Process:

Using the Recipe Editor

Batch Management

Recipe Management

Batch Management Systems

are traditionally composed

of two subparts:

One assuring the

creation

and configuration of the

recipes

, and;

The other assuring the

execution of the recipes

,

i.e., driving the equipment

to make a product according

to a production order.

Batch Management Batch Execution

Management

Batch Management Systems

are traditionally composed

of two subparts:

One assuring the

creation

and configuration of the

recipes

, and;

The other assuring the

execution of the recipes

,

i.e., driving the equipment

to make a product according

to a production order.

Batch Scheduling

When the batch size entered is greater than the defined

maximum batch size of the recipe, the Batch Scheduler opens a

dialog box to confirm the splitting into multiple batches.

Batch Execution and Supervision

InBatch directs and supervises the batch processing.

Based on the recipe procedure, InBatch validates and

activates phases to run after parameter download.

InBatch also

interfaces with the batch displays

enabling interaction on the batches

running in the system. InBatch directs and supervises the batch processing.

Based on the recipe procedure, InBatch validates and

activates phases to run after parameter download.

InBatch also

interfaces with the batch displays

enabling interaction on the batches

Batch History and Reporting

• InBatch records all batch

execution related information into a MS SQL Server database (MS SQL 2102 supported and included) and includes store & forward for uninterrupted batch records.

• InBatch leverages Wonderware

Information Server (included) with 26 Batch execution

related (SSRS*) reports published.

• InBatch records all batch

execution related information into a MS SQL Server database (MS SQL 2102 supported and included) and includes store & forward for uninterrupted batch records.

• InBatch leverages Wonderware

Information Server (included) with 26 Batch execution

related (SSRS*) reports published.

InBatch Flexible Architecture

• Scalable – from Single node to multi (redundant) Server/multi Client

• Standalone or integrated in Wonderware System Platform

• Control System independent via state interface and DA servers

• Different levels of security (standalone or integrated) and electronic signature to fulfill 21CFR Part 11 requirements

• Open Batch History database (MS SQL Server) and ArchestrA Reports

(SSRS based) via Wonderware Information (Web) Server

• API‘s for advanced or custom recipe management or automation

• Scalable – from Single node to multi (redundant) Server/multi Client

• Standalone or integrated in Wonderware System Platform

• Control System independent via state interface and DA servers

• Different levels of security (standalone or integrated) and electronic signature to fulfill 21CFR Part 11 requirements

• Open Batch History database (MS SQL Server) and ArchestrA Reports

(SSRS based) via Wonderware Information (Web) Server

InBatch System Architectures

without Wonderware System Platform

InBatch Server(s) InBatch Historian & Web Reports Redundant InBatch Server(s) PLC -I/A Series DCS InBatch Historian & Web Reports Redundant InBatch Server(s) Reporting Clients Batch DEV/RT Clients

Flexible and powerful

batch management capabilities

InBatch, Batch management integrated

with your Control System of choice

Phase 1 Phase 2

Phases are modeled

within the Control System, coordinated by InBatch

Flexible and powerful

batch management capabilities

InBatch, Batch management integrated

with your Wonderware System Platform

Phase 1 Phase 2

Phases are modeled

within the Control System, coordinated by InBatch

InBatch, Batch management integrated

with your Wonderware System Platform

Phase 1 Phase 2

InBatch, Batch management integrated

with your Wonderware System Platform

Phase 1 Phase 2

Phase 21 Phase 22

InBatch, Batch management integrated

with your Wonderware System Platform

Phase n Phase 1 Phase 2 Filling Packaging Any Process

Software Phases within System Platform

Phase 21 Phase 22

InBatch, Batch management integrated

with your Wonderware System Platform

Phase n

Phase 1 Phase 2

InBatch Events during Batch execution

Unit Proc. Run

Start Abort Done Phase Done Operation Done Phase Run Equipment Released

Phase 21 Phase 22

InBatch, Batch management integrated

with your Wonderware System Platform

Phase n

Phase 1 Phase 2

Enterprise Integration Application

Wonderware Software

The Portfolio…

Common Platform,

Model based,

Modular

Deployment,

Comprehensive

Offering…

Production & Performance Mgt. Applications

SmartGlance

Your Enterprise Systems

Your Enterprise Systems

Common Platform,

Model based,

Modular

Deployment,

Comprehensive

Offering…

Your Manufacturing Processes here

Your Manufacturing Processes here

InBatch Value - Proposition & Benefits

InBatch provides unmatched capabilities:

• Batch execution management for multiple batches at the same time • Equipment and connection arbitration, allocation and release

• Comprehensive electronic batch record (EBR) and reporting capabilities out of the box

• Facilitates 21CFR Part 11 compliance

InBatch provides flexibility and production tracking

• Recipe procedure changes

• Material formulation changes

• Complete material genealogy - US and EU standards, IFS, Bio-terrorism

InBatch & Wonderware System Platform – a

unique

Manufacturing Solution

InBatch provides unmatched capabilities:

• Batch execution management for multiple batches at the same time • Equipment and connection arbitration, allocation and release

• Comprehensive electronic batch record (EBR) and reporting capabilities out of the box

• Facilitates 21CFR Part 11 compliance

InBatch provides flexibility and production tracking

• Recipe procedure changes

• Material formulation changes

• Complete material genealogy - US and EU standards, IFS, Bio-terrorism

InBatch & Wonderware System Platform – a

unique

InBatch Roadmap

Soon:

•

InBatch 2012 R2

SP1

•

Scope: Fixes and maintenance for InBatch 2012 R2

•

Planned delivery: 1st half of 2014

Next:

•

InBatch 20XX

•

Scope: SPECs and BOM from external systems

(e.g. Wonderware MES)

Soon:

•

InBatch 2012 R2

SP1

•

Scope: Fixes and maintenance for InBatch 2012 R2

•

Planned delivery: 1st half of 2014

Next:

•

InBatch 20XX

•

Scope: SPECs and BOM from external systems

(e.g. Wonderware MES)

Wonderware MES Software Wonderware Recipe Manager Professional

Recipe Management & Execution

Strategy

Recipe Manager Professional =

• Formula Management • Procedure Management • Parameter Download • Recipe Execution

• Electronic Batch Record

• Standalone (OPC UA to controller) • Integrated with System Platform • Integrated with Wonderware MES

Wonderware Recipe Manager Professional NEW Wonderware InBatch Software

Recipe Manager Professional =

• Formula Management • Procedure Management • Parameter Download • Recipe Execution

• Electronic Batch Record

• Standalone (OPC UA to controller) • Integrated with System Platform • Integrated with Wonderware MES