Topic 1.1.6: Managing Recipe, Batch & Material

  • Materials Tracking Management\
    • Materials Tracking Management includes the ability to define materials as ingredients, intermediates, finished goods, by-products, and others. The ability to define characteristics is provided for each material entered into the system.
  • Recipe Management
    • The batch control system provides a recipe management system that enables Master Recipes to be constructed and edited. Master recipes are not process line specific, but rather are equipment independent. They can be assigned to any process line (train) that has units belonging to the classes of process equipment defined in the recipe.
    • A master recipe becomes a Control Recipe as the units defined in the train are dynamically allocated and used in producing a batch.
    • A master recipe is not size specific, but is scalable to the batch size defined by production scheduling. All formula quantities for ingredients, intermediates, by-products, and finished goods are entered as either actual quantities or can be expressed as a percent of the total batch size.
    • Quantities expressed in percentages are scaled by the batch management system when the batch is executed.
  • Batch Management
    • Batch management consists of scheduling and initializing batches, coordinating the execution of batches with the control system interfacing with operators, and storing all batch activity. These functions are provided by the Batch Manager, Batch Scheduler, and Batch Display programs.
    • Scheduling – The Batch Manager's scheduling capability is to dispatch batches that are ready to run to plant floor operators. Scheduling involves the manual entry of the batch identification, master recipe, batch size, and Train (process line) into the Batch Scheduler. Once entered, the batch can be initialized.
    • Initialization – Each batch must be initialized before it is executed. The initialization process involves validation of the recipe, checking if the Train exists, checking if the bulk materials defined in the recipe are available in the Train, ensuring that the recipe's equipment requirements are satisfied by the Train, and verifying that the Process Model database is compatible with the recipe.
    • Batch and Unit Management – Batch Manager directs and supervises the execution of each batch. The Batch Manager is a recipe interpreter and control system enabler. Based on the recipe's procedure, blocks of control software, referred to as phase blocks, are signaled to execute by the Batch Manager. Phase block control logic, located in the control system, is responsible for controlling the process. Prior to enabling each phase block, the Batch Manager verifies that the phase block is ready to be executed. If so, phase parameter values are downloaded to the block; then the block is started.
Last modified: Tuesday, 28 April 2020, 12:17 PM