Batch Forensics: The Case for Procedural Unit Tags

A Unit Tag is a class-based tag that identifies a characteristic of a unit.

The values of these tags are usually associated with information captured via the control systems analog and digital Input cards, signals like Temperature, Weight, Pressure, Level, Conductivity, pH, Level Switch, etc. Other unit tags can contain the status, state, material of construction, or any other user-defined attribute that can enhance the recipe editing capability and execution.


Read More | Posted In: Bakery Industry, Beverage Industry, Distilleries, Food Industry

Batch Forensics: The Case for Link Groups – Class based Unit Synchronization

To coordinate activities between units, take advantage of product functionality to greatly reduce controller code. Programing and unit coordination are used during activities such as material transfer from one unit to another and may be used to coordinate recipe pause points in a unit while the recipe of another unit reaches the desired step, or may be used to transfer process data from one unit to another for further evaluation, etc.

Using product functionality to create a class-based solution while minimizing programming greatly simplifies the complexity of the code. The product functionality consists of link groups and Phase logic phase requests (PXRQ for phase manager phases and RQ for classic OPC phases).

To better understand its usability, we will use a sample process consisting of units capable of transfer material with each other, One to Many, Many to One, Many to Many. In any of these examples, keeping track of who the groups involved in a synchronization can be as simple as specifying the required pairs (more than two concurrent can be done as well) in the procedural (recipe) model.

Let’s look at several scenarios:


Read More | Posted In: Batch Boosters, FactoryTalk Batch

Batch Forensics: Additional Report Parameters Enhance Process Performance

Understanding your process performance starts with having unambiguous data that is contextualized. This data provides information that quantifies and qualifies the different aspects that provide insight into the overall system performance. This data ends up in a repository and gets analyzed to produce actionable information and these reports may look at different aspects of the activities required to make products or to clean the equipment. By looking at the process from the ISA 88 and ISA95 point of view, we are able to provide additional context to the information for which the basic activities are reporting.

Additional information may be added to provide more insight into the activities related to:

  • Quality – (amounts, tolerances, durations, temperatures, lethality, etc.)
  • Cost- (materials, energy, personnel, equipment, etc.)
  • Material information – (lot ID, material properties, storage locations, etc.)
  • Personnel – (who is performing tasks, signoffs, etc.)
  • Energy – (transport, heat/cool, mix, etc.)
  • Equipment – (raw material source, equipment utilization, portable equipment information.)

– as well as other aspects that can be used to make informed decisions. (more…)

Read More | Posted In: Bakery Industry, Beverage Industry, Blogs, Chemical Industry, Food Industry, Life Science Industry, Metals