Maximizing efficiency in production management from order generation through execution and ideal bat

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Maximizing efficiency in production management
from order generation through execution and ideal
batch and recipe management

• BluESP User Conference May 2007
• Jean-Michel Pin
• PME Product Manager

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aspenONE Coverage of ISA-S95
Sales receives an order for a product enters
into an enterprise system
Aspen Integration Infrastructure Aspen
Operations Domain Model
Planners/Schedulers/Ops Managers will determine
how to fulfill the order
Aspen Operations Domain Model Aspen
Schedule Insight
Order is completed, product moved to inventory or
to the customer and production reconciled
Aspen Plant Scheduler
Operations will then push the order into
manufacturing for execution
Aspen eBRS Aspen ODM
Aspen Process Explorer Aspen OpsKPI Aspen Golden
Batch Profiler
Aspen eBRS
Based on assets available (equipment, people,
inventory) the production schedule for the order
is created
Aspen eBRS Aspen ODM
Aspen IP.21 Aspen Batch.21
Aspen eBRS
As product being manufactured, status of assets,
consumption of raw materials and inventory of
finished goods is reported back
Plant Connectivity through CIM-IO / BXE
Work activities moved out to operations for
execution according to schedule
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S95 - Definition Management Aspen eBRS

• This module allows the process engineer or
  chemist to manage and define master recipes that
  consist of a number of unit procedures, basic
  phases, documents and parameters. While basic
  phases represent a set of individual actions that
  are executed at a given time-place, documents
  represent either information for the attention of
  the operator or are used for reporting purposes.

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S95 - Definition Management Aspen eBRS
relationship between Master recipe, Procedures,
Unit procedures, Operations and Basic Phases
Aspen BatchPlus Recipe
Templates

• The recipe and basic phases definition
  effectively describe the operators workflow and
  related actions, i.e. dictate
• What has to be done (i.e. what sequence of
  operations)?
• Where it can be executed (i.e. which
  workstations can be used)?
• Who can perform the operations (i.e. which users
  or operators are allowed to take actions and
  execute the operation)?

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S95 - Production Dispatching Aspen eBRS

• Production dispatching provides the shop-floor
  with a management view of the activities allowing
  optimal asset and personnel allocation,
  activities synchronization and increasing
  real-time manufacturing visibility.

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S95 - Production Dispatching Aspen eBRS

• The Work Order Dispatch module allows the
  process engineer, chemist or production
  supervisor to manage the work orders and to
  visualize or print their associated documents.
• In addition, the supervisor can also
• Create a work order manually and review the work
  orders automatically created by an ERP system.
• Dispatch a work order to a given workstation for
  execution.
• Control the execution of all the work orders as
  information of basic phases being currently
  executed or already completed for all
  workstations is displayed in the work order
  dispatch module.

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S95 - Execution Aspen eBRS

• Workflow management is about executing a recipe
  and controlling the workflow of activities in the
  workshop operator guidance, PLC/DCS phase
  trigger, equipment status check

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S95 - Execution AeBRS

• Basic Phases are executed on the plant floor
  according to the rules and actions defined in the
  recipe procedure logic.
• Execution of basic phases generates the data to
  populate the Batch Record. In case of regulated
  industry e-signature will be required.
• Batch Record stored in Aspen Batch.21
• Master Data store in Aspen ODM (Equipments and
  Materials)

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S95 - Resource ManagementAspen ODM

• Resource management provides a real-time and
  historical management view of assets materials
  for optimal resource allocation.

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S95 - Resource ManagementAspen ODM

• It manages the status, the locations and the
  validity of equipments. It ensures the correct
  equipment is utilised at each manufacturing stage
  (through bar code identification) and prevents
  use of incorrect or disallowed (e.g. unclean or
  un-validated) equipment items
• It manages Material Lot data track quantity,
  status, sub-lot data and keeps track of changes
• It uses Aspen eBRS for Industry Specific front end

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S95 Data Collection AnalysisAspen InfoPlus.21
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S95 Data Collection AnalysisAspen Batch.21
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Aspen Batch Event Extractor

• Reads directly from IABatch, AIM, RSBatch, DeltaV
  Batch Historian, OpenBatch databases
• GUI allows high level of customization of Aspen
  Batch.21 characteristics
• Aspen Batch.21 configuration auto-generated
• Configuration maintained in SQL-Server database
• Extendable to any relational data source
• New on the DVD for V2006

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Architecture/Approach
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S95 Analysis TrackingAspen OpsKPI
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S95 AnalysisAspen Process Explorer
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S95 AnalysisAspen Event.21

• Event.21 handles event and alarm tracking within
  InfoPlus.21 and monitors process variables to
  determine when event conditions occur. Users
  also can manually enter events. Events can be
  viewed through displays in Aspen Process Explorer
  and users can enter comments associated with
  specific events.

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S95 Analysis TrackingAspen Q (SPC/SQC)
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S95 Analysis TrackingAspen Golden Batch
Profiler
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S95 Analysis TrackingGolden Batch Profiler

• Aspen Golden Batch allows operators to monitor in
  real-time process parameters against an ideal or
  golden profile
• The Profile has a target value and limits.
• The Profile applies to an Aspen Batch.21
  sub-batch, which can be a phase, operation or the
  whole batch. You can have multiple profiles for
  each batch.
• The envelope or profile is computed from previous
  best batches or can be imported from an external
  application

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S95 Tracking Scheduling Insight

• Provide scheduled versus actual view of
  production includes drill down to batch detail
  data.

Providing actual values to support Gantt view of
a schedule that overlays Schedule vs. actual.
Roll up sub-lot inventory production and track
good and total inventory produced
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• Questions?

Jeanmichel.pin_at_aspentech.com