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

1. The Secret Life of S88‘Cause hey, everyone needs aanother acronym to remember Russell Czolgosz(Chōl·gŏsh) MTU ChE class of 1999 Lead Automation and Controls Engineer Dow Corning Corp Modified by DWC 1-11-2010 for CM4120

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 Allocation Arbitration Outline BATCH Recipe Procedure Operation The Secret Life of S88

3. Need Predictable Product Quality Variation in feedstocks Poor control of manufacturing processes Human error Differences between processing locations Overcome 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 information Would Like New Markets/ New Products Need “Agility” but have a dedicated system Rigid design creates long product/process development times Typical Manufacturing Challenges The Secret Life of S88

4. Design equipment for a specific process/ product Develop procedures to make that product Implement process control to meet the product requirements and fit the SOP At completion all aspects of the SOP/ product/ equipment/ control are rigid, hard-coded, and fixed This type of implementation: Hinders Process Improvement Prohibits Manufacturing Agility Prevents Asset Optimization The goal of S88 is to prevent these roadblocks. Traditional Process Development The Secret Life of S88

5. 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 Secret Life of S88

6. 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 The Secret Life of S88

7. 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 The Secret Life of S88

8. Benefits of an S88 Solution? • Modularity allows for easier replication and better ROI • Design concepts make validation easier 3. S88-aware solutions help track product and process data 4. Gathering requirements from customers/ conveying requirements to vendors is easier 5. Provides guidelines on how to recover from abnormal events The Secret Life of S88

9. 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 The Secret Life of S88

10. Improved Batch Processing Throughput Cost • 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 The Secret Life of S88

11. Steps in Applying S88 Learn the terminology Break the process down into appropriate components Identify the steps necessary to produce the product Identify recipe parameters Tie the recipe to the procedures Map the procedure to the processing equipment The Secret Life of S88

12. S88 Recipe TypesWhat we want to make, what equipment we need, and how we want to do it The Secret Life of S88

13. 4 Recipe Types General Recipe 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 May be transformed into Site Recipe May be transformed into Master Recipe May be transformed into Control Recipe Ref. S88.01 Fig.8 – Recipe types The Secret Life of S88

14. Recipe Definition • 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 The Secret Life of S88

15. Process Model Physical Model Procedural Control Model Control Activity Model Applying S88 – 4 Models Defined The Secret Life of S88

16. S88The Process ModelDescribes 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). The Secret Life of S88

17. Process Model General and Site Recipe procedures will be based on the “Process Model” Process Make PDMS Consists of an ordered set of Polymerize Remove Low Boilers Cool Product Process Stage Consists of an ordered set of Prepare Reactor Charge React Process Operation Consists of an ordered set of Add req’d 245 Fluid Add req’dEndblocker Heat to 140 C Process Action The Secret Life of S88

18. S88The Physical ModelThe equipment used to perform the process.Defines the hierarchy of the equipment. The Secret Life of S88

19. Physical Model Consists of all the production and supporting equip necessary to make a batch Enterprise Process Cell Process Cell A major piece of equipment within a process cell that performs a specific task Site Unit Unit Grouping of equipment & control modules that together perform a minor task Area Equipment Module Equipment Module Basic discrete and analog control (output) devices Control Module Control Module Subdivision of the corporation’s PHYSICAL ASSETS organized in a hierarchy of equipment that consists of several integrated levels MTU PSCC Houghton PDMS Reactor Unit Solvent Recovery Unit Chem Sci Building Agitator Temp Feed Discharge Agitator Controls Outlet valve Temp Controller The Secret Life of S88

20. Material Selection Material Charging Pressure Control Mix Unit Temperature Control Discharge and Recirc Equipment Module Pump Control Module An Example Process Cell Process Cell FT M PT TT FT The Secret Life of S88

21. Defining a Unit Process Cell Unit Equipment Module Control Module • 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 The Secret Life of S88

22. Examples of Units: Is Nota Unit Is a Unit Mix-making batch tank 4 Pasteurizer 4 Reactor 4 Pump 4 Ingredient storage tank 4 Washing machine 4 Kitchen blender 4 Refrigerator 4 Dishwasher 4 The Secret Life of S88

23. Mix Equipment Modules Process Cell Unit Equipment Module Control Module • Equipment modules group devices for performing one or more specific minor processing activities • Equipment modules run portion(s) of a recipe M FT Material Charging Equipment Module The Secret Life of S88

24. Material Selection TemperatureControl Control Modules Process Cell Unit Equipment Module Control Module • 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 TT The Secret Life of S88

25. Unit Equipment Module Control Module 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 Process Cell The Secret Life of S88

26. S88The Procedural Control ModelSequence 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 The Secret Life of S88

27. Procedural Control Model • Defines the process strategy for making a batch within a process cell • A hierarchy of the actions that are performed to complete a batch Procedure • Defines the actions that are performed on a Unit • Consists of an ordered set of Operations that control the functions of the unit Unit Procedure • Defines an ordered set of phases that are arranged to perform a particular function within a unit • -One or more operations could occur simultaneously Operation • Defines a simple action or command to set or change the state of an Equipment Module • -Can be subdivided into steps and transitions Phase Make PDMS Polymerize Remove Low Boilers Cool Product Prepare Reactor Add Ingredients Heat Add 245 Add Endblocker The Secret Life of S88

28. Procedural Control Model Example Phases are the workhorses. Other levels simply group, organize, and direct phases. Make Toothpaste Procedure Unit Procedures Make Paste Make Gel Swirl Prepare Tank Add Ingredients React Operations Add Water Add Fillers Add NaF Phases The Secret Life of S88

29. The Automation Specification: Physical Model Procedural Control Model Enterprise A document that describes how Equipment Modules are related to a Unit and how the Phase(s) control each Equipment Module Site Procedure Area Unit Procedure Process Cell Unit Operation Equipment Module Phase Control Module The Secret Life of S88

30. 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 The Secret Life of S88

31. S88 – Model Relationships Procedural Control Model Physical Model Process Model Process Procedure Process Cell Provides process functionality to carry out a… Combined With a + Process Stage Unit Procedure Unit(s) Provides the functionality to carry out a… + = Process Operation Operation(s) Unit(s) + = Process Action Phase(s) Unit(s) Phase(s) + Equipment Module(s) Process Action = Ref. S88.01 Fig.7 – Procedural control/equipment mapping to achieve process functionality The Secret Life of S88

32. Separate Models Add Flexibility 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 The Secret Life of S88

33. Summarizing the 1st Three Models Corporate sends a General Recipeto my Site • Convert General Recipe to a Site Recipethen • 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 The Secret Life of S88

34. 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 Phaseaccomplishes, 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 The Secret Life of S88

35. Batch of Cookies! Batch Size Control Recipe Formula Inputs Recipe Parameters Phases Transition Expression • Original Nestlé Toll House Chocolate Chip Cookies • Makes about 5 dozen cookies • Ingredients: • 2 1/4 cups all-purpose flour • 1 teaspoon baking soda • 1 teaspoon salt • 1 cup (2 sticks) butter, softened • 3/4 cup granulated sugar • 3/4 cup packed brown sugar • 1 teaspoon vanilla extract • 2 large eggs • 2 cups (12-ounce package) NESTLÉ® TOLL HOUSE® Semi-Sweet Chocolate Morsels • 1 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. Recipe Header Master Recipe Procedure Operations The Secret Life of S88

36. S88The Control Activity ModelThe 4th Model“Cactus Model”Shows relationships between control activitiesDescribes flow of information throughout the enterprise The Secret Life of S88

37. Control Activity Model Production Planning and Scheduling Master Recipe Master Recipe Batch Schedule Recipe Management Production Information Management Process Management Batch Schedule Batch Progress Master Recipe Batch and Process Cell Information Unit Supervision Unit Recipes and Commands Batch Status Batch and Unit Information Process Control Commands Statuses Process Data Personnel and Environmental Protection Commands Below this line is outside S88 Scope Statuses The Secret Life of S88

38. Overall Value of S88 • 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 The Secret Life of S88

39. 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 The Secret Life of S88