2012 Honeywell Users Group Americas Sustain.Ability. Batch Management Chris Morse, Siva Sundararajan, Frank Offenbacher 1 Groundbreaking Technology Shaping Batch Solutions • New Experion Batch Manager Functionality – – – – – Class based Master Recipes Recipe Builder Batch Application Services New Server peer responder Migration from TotalPlant Batch (TPB) in Orion • What you will learn if you are: – Existing batch user • Business benefits of new batch functionality built into Experion • Sustain.Ability with migration path from TotalPlant Batch – User with a new batch or sequential application • Powerful batch functions built into Experion • Benefits over server-based batch applications 2 Batch Manufacturing trends • Tighter Supply Chain Integration – Planning, Scheduling, MES, and ERP Integration • Need for Greater Plant and Recipe Flexibility – Faster new product development & deployment – More/more complex recipes - move from commodity to specialty products • Increase Production and Higher Quality Products – Better use of equipment and automation • Lower Operating and Lifecycle Costs – Modular ease of use software for configuration and execution • Enhanced Process and Product Understanding – Multi-process, product and plant analysis and optimization 3 Market Pressure to do More with Less Experion Batch Manager Moving batch execution from here Batch Server TotalPlant Batch ACE or here C200E or here 4 C300 to here Reduced Hardware & Lifecycle Costs Batch Manager Business Benefits • Batch Manager delivers more on-spec product from a batch plant with lower engineering & support costs • Sustained operations over server based applications: – Reduce unplanned downtime • Reduce cost of rework/disposal of problem batches • Reduce disruption to production from server problems • Improved availability with bumpless redundancy – Improved plant productivity • Reduced unproductive time between steps • Typical plant calculates an annual increase in throughput of 3% to 5% – Improved efficiency through Experion integration • Standard Experion displays in all user environments • Reduced recipe maintenance with Class Based Recipes • Powerful reporting with Procedure Analyst 5 } New in Orion Reducing Lifecycle Costs Server Based Lifecycle $ Operability Special skills Batch Manager Microsoft Alignment Management of Recipes Lifecycle $ Operability Single Operator Environment Special Skills Single Engineer Environment Management of Recipes Class Based Recipes Routine Change Routine Change Single point maintenance Single Point of Failure 6 Single Point of Failure Bumpless Redundancy Reduced Lifecycle Costs through Integrated Technology Sustaining Knowledge -Master Recipes Recipe 1 Mixer 1 Recipe 2 Mixer 1 Recipe 3 Mixer 1 Recipe n Mixer 1 Recipe 1 Fermenter 1 Recipe 2 Fermenter 1 Recipe 3 Fermenter 1 Recipe n Fermenter 1 7 Sustaining Knowledge -Master Recipes Recipe 1 Mixer 1 Recipe 2 Mixer 1 Recipe 3 Mixer 1 Recipe n Mixer 1 Recipe 1 Recipe 1 Mixer 2 Milk Homogenise Homogenise M1 M2 Recipe 1 Fermenter 1 Recipe 2 Fermenter 1 Recipe 3 Fermenter 1 Recipe n Fermenter 1 Recipe n Recipe n Mixer 1 Recipe 1 Fermenter 1 Recipe 2 Fermenter 1 Recipe 3 Fermenter 1 F1 F2 Class Based Recipes 8 Recipe 2 Recipe 2 Mixer 2 Recipe 3 Recipe 3 Mixer 21 Reducing Lifecycle Costs with Master Recipes Recipe n Fermenter 1 Business Integration - Batch Application Services Master Recipe: GR1102 Batch ID: TD12345 Batch Size: 75% Initiator: 1.3 Kg Initiator: 1.9 Kg Unit Mixer: M1 MES/ERP: Master Recipe: GR1102 Batch ID: TD12345 Batch Size: 75% Initiator: 1.9 Kg Unit Mixer: M1 Experion Server MES C300 9 C200E New in Orion Improved Production Efficiency with ERP/MES Integration Control Builder + Recipe Builder – different roles Control Engineer Formulator New In Orion • Segregates Recipe Building role from Control Building role • Reduce maintenance time & avoid errors • RCMs & Master Recipes only built assigned & loaded in Recipe Builder • Control Builder remains tool to do everything 10 More efficient Recipe Management through Tool Segregation Lifecycle Sustainability - Migration • Legacy Batch Products can be migrated to EBM TotalPlant Batch – TotalPlant Batch (TPB) – Batch Supervisor – BMS • Retention of HPM using server peer responder • Automated Recipe Migration TPB > Batch Manager – Equipment Model – Recipes • Equivalent License Entitlement for TPB via SE&SP • Specialist resources for migration assessment 11 Experion Batch Manager Experion TPB C200 to EBM Migration S88 Procedure/Unit Procedure/Operation Process Server C200(R) TPB Servers C200(R) Experion Stations C200E (R) S88 Procedure/Unit Procedure/Operation S88 Phases 12 TPB Migration to EBM C300 HPM Retained GUS EST S88 Procedure/Unit Procedure/Operation ESVT Batch Controller TPB APP Warm Standby C300(R) LCN NIM (R) ENIM (R) LCN tag.parameter read/write HM EHPM (R) HPM (R) S88 Phase level PMCL S88 Procedure/Unit Procedure/Operation LCN tag.parameter read/write LCN tag.parameter read/write 13 Lifecycle Sustainability through Continuous Evolution Plant Expansion EBM Summary Experion Batch Manager 14 Other Batch Products Your Business Benefit Reliable, deterministic Batch Execution in the controller Batch Execution at a server Production reliability assured by full redundancy Production depends on warm restart or high availability server platform Fast, deterministic transitions between procedural elements for efficient batch cycle times Longer transition times extending batch cycle times Batch out of the box configured in familiar builder for engineering & operational efficiency Additional package involving training & support No production interruptions online modification for all batch functions Shutdown required for equipment & phase configuration Easy system modifications without interruption to production Distributed batch execution in any controller Batch execution on a single server System scalability up and down Improved production reliability Improved production reliability Increased plant throughput Reduced project & lifecycle costs Continue the Conversation Online Twitter @hwusers #HUG12 Flickr LinkedIn Website HUG Live Facebook Honeywell Users Group 15 YouTube