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Process Flow Analysis for Flexible, Integrated Automation

Process Flow Analysis for Flexible, Integrated Automation. Jean Vieille Consultant – Industrial Production Control Strasbourg (France). MANUFACTURING IT Bologna, Italy March 01, 2001. Agenda. 1 - Centralized vs Distributed control 2 - Automation Challenge within Production System

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Process Flow Analysis for Flexible, Integrated Automation

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  1. Process Flow Analysisfor Flexible, Integrated Automation Jean Vieille Consultant – Industrial Production Control Strasbourg (France) MANUFACTURING IT Bologna, Italy March 01, 2001 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  2. Agenda • 1 - Centralized vs Distributed control • 2 - Automation Challenge within Production System • 3 - Flow Analysis Method • 4 - Objects collaboration • 5 - Practical use • 6 - Conclusion J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  3. - 1 - Centralized vs Distributed Control J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  4. The Powerful Tyrex… • Big brain • Centralized design • OK for steady / slow changing environment • Shortcomings • Agility • Availability • Refer to first computerized systems J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  5. …vs Stupid Bird • Limited intelligence • Mostly decentralized design • Local decision making at feather level • Cope well with unexpected situations • Inherently adaptative structure J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  6. - 2 - Automation Challenge within Production System J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  7. Ideal automation Flexibility S88 Manual Operation Capability Complexity Traditional Automation Automation Challenge Darin Flemming Lou Pillai J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  8. Production Schedule S88 : Schedule S88 : Resources S88 : Recipe S88 : Equipment Procedural Elements Product Enginnering Resources Engineering S88 in Production System Lifecycles J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  9. Forecasting, Planning And Scheduling Process Control Definition Equipment Functional Capabilities Elementary Equipment Control The Goal: I know What/How To do Flying chirping Walking Eating Love. From Goal to Labor J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  10. ISA S95 Process Control ISA S88 / IEC 61512 OPC Equipment Control IEC 61131 IEC 61499 ISA S50 / IEC 61158 Fieldbus « Intelligent » Device Scheduling hierarchy Business system MES systems SCADA systems J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  11. - 3 - Flow Analysis Method J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  12. Operator Control System Safety System Breakdown Concurrent control of actuators J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  13. Energy Sources Material Sources Material Sinks A C D B F E Energy Sinks Material and Energy Flows J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  14. Material Sources Material Sinks A C D B F E 1. Identify Containers J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  15. Material Sources Material Sinks A C D B F E 2. Identify realistic Paths J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  16. Material Sources 4 Material Sinks 1 A 5 C 3 2 3 D B F E 3. Activate or Sequence Paths to Perform Process J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  17. Product / lot A Product / lot A Product / lot A Product / lot A Product / lot A Several paths simultaneously active J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  18. - 4 - Objects Collaboration J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  19. R1: Process Control Function 1: Fill A F2: Fill B F3: Transfer B-> C Resource 1: Feeding Line R2: Tank A R3: Tank B R4: Transfer Line R5: Tank C R6: Tank D Device1 D2 D3 D4 D5 D6 From Process to Device Control J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  20. Control Measurement Fault Discrepancy Equipment level Control / Failure Limiting Actuator R2 R1 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  21. Process => Fault Allocating F1 => Fault F2 => OFF Adjacent R3 => Fault Owning R1 => Fault R2 => OFF D2 => OFF Cascading Process Cell Shut-down D1 => Fault J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  22. - 5 - Practical use J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  23. R1 & R4 un-allocated (or allocated by another Function) R1 R3 R4 R2 Function F1 « Fill tank from R2 » allocates R2 & R3 Limiting actuators – Flow Padlock Tank A1 A3 A2 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  24. Sanitary Status Padlock J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  25. Resources Breakdown & Id OPERATION Flows & Function Id Process Control Definition Operational Qualification Resources & Functions Design System Design Generic Objects Definition Equipment Control Project P&IDs J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  26. Conclusion • Truly decentralized systems are comming • All levels well addressed • Flow Analysis helps for proper physical modelling • Outstanding benefits making OOD practical • New thinking processes, may lead to difficulties with Control Engineers • Think Pipes rather than Bytes J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

  27. Information • Information available at www.frenchbatchforum.org • World Batch Forum WG4 « Flow Analysis » • See above link • www.wbf.org • Powerpoint presentation on request • jean-vieille@usa.net J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna

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