the secret life of s88 cause hey, everyone needs a another acronym to remember russell czolgosz...

The Secret Life of S88‘Cause hey, everyone needs aanother acronym to remember

Russell Czolgosz (Chōl·gŏsh)

MTU ChE class of 1999Lead Automation and Controls

EngineerDow Corning CorpModified by DWC 1-11-2010

for CM4120

New Employee Training, Midland MI June 11, 2009The Secret Life of S88 2

Background What is ISA and S88? Recipe Types 4-parts of the S88 Model

Physical Model Process Model Procedural Control Model Control Activity Model

Tying it all together

Outline


Need Predictable Product Quality Variation in feedstocks Poor control of manufacturing processes Human error Differences between processing locationsOvercome High Manufacturing Costs Low equipment utilization – difficulty in

scheduling Using old processing/control technologies Labor intensive High cost of energy Poor flow of material and informationWould Like New Markets/ New Products Need “Agility” but have a dedicated system Rigid design creates long product/process

development times

Typical Manufacturing Challenges


1. Design equipment for a specific process/ product

2. Develop procedures to make that product

3. Implement process control to meet the product requirements and fit the SOP

4. At completion all aspects of the SOP/ product/ equipment/ control are rigid, hard-coded, and fixed

This type of implementation:Hinders Process ImprovementProhibits Manufacturing AgilityPrevents Asset Optimization

The goal of S88 is to prevent these roadblocks.

Traditional Process Development


ISA – International Society of Automation S88 (or ISA 88) Batch Control Standard

Currently a 4-part standard Part 1 Models and Terminology (ANSI/ISA-88.01) Part 2 Data Structures & Guidelines for Languages

(ANSI/ISA-88.00.02) Part 3 General and Site Recipe Models &

Representation (ANSI/ISA-88.00.03) Part 4 Batch Production Records (ANSI/ISA-88.00.04) Part 5 is currently in draft

SP88 is the Batch Control Standards Committee

ISA S88 is...


The Intent of S88: Promotes modularity and flexibility Emphasizes good practices for design/

operation Provides a common concepts,

framework, models, and terminology Improve efficiency/ control of mfg.

plants (batch, semi-continuous, and continuous)

It is a guideline, NOT a compliance standard


S88 – Must be Interpreted!

S88 defines general practices Written to apply to the entire processing industry Makes suggestions and provides examples Does not list requirements

Suggests standardized modular design concepts Reusable design components Similar to object-oriented computer programming


Benefits of an S88 Solution?

1. Modularity allows for easier replication and better ROI

2. Design concepts make validation easier3. S88-aware solutions help track product

and process data4. Gathering requirements from customers/

conveying requirements to vendors is easier

5. Provides guidelines on how to recover from abnormal events


Spirit of S88

Not just a standard for software, equipment, or procedures A new way of thinking – a design philosophy

Understanding S88 will help you design better processes and manufacture better products Isolates equipment from recipes


Improved Batch Processing

Reduced batch cycle time

Increased production rate

Faster changeover More scheduled

recipes Reduced downtime Faster process

development Quicker product

launches

Reduced raw material loss

Improved batch consistency

Better equipment utilization

Less time to add/modify recipes

Lower engineering cost

Lower data capture cost

Better data availability

Throughput Cost


Steps in Applying S881. Learn the terminology2. Break the process down into

appropriate components3. Identify the steps necessary to

produce the product4. Identify recipe parameters5. Tie the recipe to the procedures6. Map the procedure to the processing

equipment


S88 Recipe Types

What we want to make, what equipment we need, and how we want

to do it


4 Recipe Types

May be transformed into

General Recipe

Site Recipe


Master Recipe


Control Recipe

Ref. S88.01 Fig.8 – Recipe types

1. General Recipe Enterprise-wide Includes product-specific

processing information 2. Site Recipe

Specific to a site Includes site-specific information

(language, raw materials, on-site limitations, etc.)

3. Master Recipe Targeted to a specific cell Starting w/ a Site Recipe, is

adapted to Process Cell-specific equipment

4. Control Recipe Consists of a Master Recipe plus

Batch ID, batch size, etc. Forever tied to a particular batch

and is specific to that batch – permits product tracking


A recipe holds the data that uniquely identifies the components of a specific product Ingredients to use Quantity of ingredients Equipment requirements The order in which tasks are performed

Recipes do not contain scheduling or equipment control information

Recipe Definition


1. Process Model

2. Physical Model

3. Procedural Control Model

4. Control Activity Model

Applying S88 – 4 Models Defined


S88The Process Model

Describes the hierarchical ordering of process functionality needed to produce a

batch.

Is not equipment specific – very conceptual.

Used to develop the recipe procedures section in the General and Site Recipes

(high-level recipes).


Process Model

Process Stage

Process Operation

Process

Process Action

General and Site Recipe procedures will be based on the “Process Model”

Consists of an ordered set of



Make PDMS

PolymerizeRemove Low BoilersCool Product

Prepare ReactorChargeReact

Add req’d 245 FluidAdd req’d EndblockerHeat to 140 C


S88The Physical Model

The equipment used to perform the process.

Defines the hierarchy of the equipment.


Physical Model

Enterprise

Site

ProcessCell

Unit

AreaEquipment

Module

ControlModule

ProcessCell

Unit

EquipmentModule

ControlModule

MTU

Houghton

Chem Sci

Building

Consists of all the production and supporting equip necessary to make a batchA major piece of equipment within a process cell that performs a specific task

Grouping of equipment & control modules that together perform a minor task

Basic discrete and analog control (output) devices

PSCC

PDMS Reactor Unit

Solvent Recovery Unit

AgitatorTempFeedDischarge

Agitator Controls

Outlet valveTemp Controller

Subdivision of the corporation’s PHYSICAL ASSETS organized in a hierarchy of equipment that consists of several integrated levels


An Example Process Cell

Mix

DischargeandRecirc

Pressure Control

Temperature Control

Material Charging

Material Selection

M

FT

TTPT

Pump

ControlModule

EquipmentModule

Unit

ProcessCell

FT


Defining a Unit Batching cannot occur without units

Batching occurs in units Units perform one or more major processing

activities A unit is used on only one batch at a time

A Unit runs a recipe Combine ingredients, or perform a reaction Adds value to your product or intermediate

Units function independently of each other

ControlModule

EquipmentModule

Unit

ProcessCell


Examples of Units:

Mix-making batch tank

Is a Unit

Is Not a Unit

Reactor

Pump

Ingredient storage tank

Washing machine

Kitchen blender

Refrigerator

Dishwasher

Pasteurizer

4

4

4

4

4

4

4

4

4


Equipment Modules

Equipment modules group devices for performing one or more specific minor processing activities

Equipment modules run portion(s) of a recipe

Material Charging Equipment Module

FT

ControlModule

EquipmentModule

Unit

ProcessCell

MixM


Control Modules

Control modules “connect” software to the process through sensors and actuators

Act as a single entity from a control standpoint Carry out Basic Control – they do not contain

procedural control

ControlModule

EquipmentModule

Unit

ProcessCell

Temperature Control

TT

Material Selection


Physical Model is Collapsible

Although a process cell must contain at least one unit:

A control module does not have to be part of an equipment module to be part of a unit

A unit can “own” control modules directly

ControlModule

EquipmentModule

Unit

ProcessCell


S88The Procedural Control

Model

Sequence of steps necessary to produce a batch.

Defines the sequential control that enables equipment to perform the

process task.

Used to develop the Recipe Procedures section of the Master Recipe

The specific control setpoints, quantities, controller modes, etc.

required to make a defined quantity of a certain product


Procedural Control Model

Procedure

UnitProcedure

Operation

Phase

Defines the process strategy for making a batch within a process cell

- A hierarchy of the actions that are performed to complete a batch

Defines the actions that are performed on a Unit

- Consists of an ordered set of Operations that control the functions of the unit

Defines an ordered set of phases that are arranged to perform a particular function within a unit-One or more operations could occur simultaneously

Defines a simple action or command to set or change the state of an Equipment Module-Can be subdivided into steps and transitions

Add 245Add Endblocker

Prepare ReactorAdd IngredientsHeat

PolymerizeRemove Low BoilersCool Product

Make PDMS


Procedural Control Model Example

MakeToothpaste

UnitProcedures

Operations

Phases

Procedure

Make Paste

PrepareTank

Add Water

Make Gel Swirl

AddIngredients

React

Add Fillers Add NaF

Phases are the workhorses.Other levels simply group,

organize, and direct phases.

Phases are the workhorses.Other levels simply group,

organize, and direct phases.

New Employee Training, Midland MIThe Secret Life of S88 29June 11, 2009

The Automation Specification:

A document that describes how Equipment Modulesare related to a Unit and how the Phase(s) control each Equipment Module

Control Module

Equipment Module

Unit

Process Cell

Area

Site

Enterprise

Phase

Operation

Unit Procedure

Procedure

Physical Model

Procedural Control Model


S88 Models Tie Together thru Mapping

Relates the procedural control model to the physical model to provide the processing

described in the process model

Involves MAPPING of Procedural Elements into Physical Entities


S88 – Model Relationships

+

Provides the functionality tocarry out a…

Ref. S88.01 Fig.7 – Procedural control/equipment mapping to achieve process functionality

Process Stage

Process Operation

ProcessProvides processfunctionality

to carry out a…

Unit(s)

Unit(s)

Unit(s)

Equipment Module(s)

Process Cell

Unit Procedure

Operation(s)

Phase(s)

Phase(s)

Procedure

+

CombinedWith a

=

=

=

+

+

Process Action

Process Action

Procedural Control Model Physical Model Process Model


Separation of Recipe, Procedures, Equipment/ Basic Control into separate models:

Each component is maintained as an entity Changes in the Recipe do not necessarily

require changes to the Phase Logic Changes to the Phase Logic do not

necessarily require changes to the Recipe Changes to physical equipment do not

necessarily require changes to the other models

Separate Models Add Flexibility


Corporate sends a General Recipe to my Site Convert General Recipe to a Site Recipe then Convert Site Recipe to a Master Recipe, for

each suitable cell, complete with setpoints, timing, quantities, tolerances, etc.

When we make a Batch, the Master Recipe gets transformed into a Control Recipe

allocate specific equipment create a batch identifier make the product, record all processing

parameters Control Recipe forever tied to that batch of

product

Summarizing the 1st Three Models


In our plant, we define: Physical Model (what Units and Equipment

Modules we have and the Basic Control that operates each)

Procedural Control Model (all the Phases that each Equipment Module can be in, what each Phase accomplishes, and the sequence of operations)

Mapping the Physical Model onto the Procedural Control Model produces the functionality described in the Process Model

Process Model describes what Process Actions will occur in each Phase of the process

Summarizing the 1st Three Models


Original Nestlé Toll House Chocolate Chip Cookies

Makes about 5 dozen cookies

Ingredients: 2 1/4 cups all-purpose flour1 teaspoon baking soda1 teaspoon salt1 cup (2 sticks) butter, softened3/4 cup granulated sugar3/4 cup packed brown sugar1 teaspoon vanilla extract2 large eggs2 cups (12-ounce package) NESTLÉ® TOLL HOUSE® Semi-Sweet Chocolate Morsels1 cup chopped nuts

Directions:

· PREHEAT oven to 375° F.

· COMBINE flour, baking soda and salt in small bowl.

· Beat butter, granulated sugar, brown sugar and vanilla extract in large mixer bowl until creamy.

· Add eggs one at a time, beating well after each addition.

· Gradually beat in flour mixture. Stir in morsels and nuts. Drop by rounded tablespoon onto ungreased baking sheets.

· BAKE for 9 to 11 minutes or until golden brown. Cool on baking sheets for 2 minutes; remove to wire racks to cool completely.

Operations

Procedure

Batch of Cookies!

FormulaInputs

Control Recipe

Phases

Recipe Parameters

Batch Size

Master Recipe

Transition Expression

Recipe Header


S88The Control Activity Model

The 4th Model

“Cactus Model”

Shows relationships between control activities

Describes flow of information throughout the enterprise


Control Activity Model

ProductionInformation

Management

RecipeManagement

ProductionPlanning andScheduling

ProcessManagement

UnitSupervision

ProcessControl

Personnel andEnvironmental

Protection

Below this line is outside S88 Scope

ProcessData

Batch and Process

Cell Information

Batch Progress

Batch Schedule

MasterRecipe

MasterRecipe

MasterRecipe

BatchSchedule

Batch and UnitInformation

Batch Status

Statuses

Statuses

Commands

Unit Recipes and Commands

Commands


Permits easy product customization Color, level of impurities, packaging, viscosity,

composition, etc. Facilitates rapid product change-over

Helps identify suitable assets at different sites

Allows for easy recipe conversion into local languages

Remember: S88 is only one element in a system of manufacturing

Overall Value of S88


References

Applying S88 Batch Control from a User’s Perspective, Jim Parshall and Larry Lamb, ISA, Research Triangle Park, NC, 2000.

ISA S88.01-1995 (R2006) Batch Control Part 1: Models and Terminology, ISA, Research Triangle Park, NC, 2006.

World Batch Foundation, www.wbf.org International Society of Automation,

www.isa.org

http://www.wbf.org/

http://www.isa.org/

the secret life of s88 cause hey, everyone needs a another acronym to remember russell czolgosz...

Documents

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requirements n

terminology n

scheduling n

flexibility n

new employee training

midland mijune

design operation n