Integrated batch operation improvement Modelbased advisory system for recipe correction and scheduli

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Integrated batch operation improvementModel-based
advisory system for recipe correction and
scheduling

• Javier Romero
• Zofia Verwater-Lukszo
• 4-07-2003

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Contents

• Introduction
• Two key concepts
• Recipe Adaptation Set (RAS)
• Plant Adaptation Set (PAS)
• Integrated advisory criterion
• Simulated application
• Demonstration advisory system

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Introduction - assumptions

• Multi-product batch plant (flow-shop)
• Disturbances at recipe and/or scheduling level
• Decision makers schedulers and/or operators
• Need for an integrated advise plant-wide recipe
  modifications as well as modifications in the
  actual plant schedule-timing

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Multi-product batch plant
Week 1 / Product A
Week 2 / Product B
All products go through all pieces of equipment
in the same order. A multi-product plant is
usually employed to produce similar products
(different grades).
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Recipe Adaptation Set (RAS)

• Related to a Master Recipe at least one of the
  process phases is flexible
• Statistical process model for the flexible phase

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Recipe Adaptation Set (RAS)

• RAS for the flexible phase process model,
  criterion to optimize the phase, constraints
• Master Recipe as defined by S88 but for the
  flexible phase process model replaces
  specification of the nominal recipe items
• Equipment requirements
• Recipe items (inputs, process parameters
  outputs) including processing time

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Plant Adaptation Set (PAS)

• Describes the plant resources management
• Master schedule
• Number sequence of orders, delivery time for
  each order
• Each order connected to a Master Recipe / RAS
• Constraints with respect to starting times
  batches and phases

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Integrated advisory criterion ?J

• J criterion optimized during recipe- (RAS) and
  plant-model (PAS) development
• ?J Penalty (changes in recipes delivery
  times)
• ?J ? min

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Pre-defined scenarios for recipe readjustment

• Ignore disturbances ?t0 ?m0, but ?qlt0
• Manipulate recipe items to meet specification
  ?tgt0 ?m0 and ?q0 for the disturbed
  order/recipe
• Optimize integrally ?topt ?mopt, ?qopt for
  all orders

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Simulated application

• Multi-product plant
• 10 orders
• 4 units
• 4 products/recipes each with four phases
• flexible phase differs per recipe
• ZW-policy

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Demonstration
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