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FactoryTalk® Batch Software Suite
Batch Management for Flexible Production Needs
The FactoryTalk Batch Software Suite,
comprised of three key modules,
enables you to develop batch control
systems that support your flexible
production needs. The key benefits
of each module include:
FactoryTalk Batch (pages 2-3)
• Introduce new products or make
changes to existing product lines
• Improve quality and consistency
of your product by executing a
repeatable process
• Simplify data collection and batch
reporting for compliance, process
improvement, and track & trace
FactoryTalk eProcedure® (page 4)
• Improve productivity by
seamlessly integrating manual
work instructions into the
automatic process
• Link to electronic production
documents such as operating
procedures, material safety
data sheets, and equipment
maintenance manuals
FactoryTalk Batch Material Manager
(page 5)
• Reduce system engineering costs
by integrating real-time material
management capabilities into
your batch process
• Simplify plant-level material
management and tracking of
material lots, storage containers,
locations, and material properties
Additional Features (page 6)
Overview
The FactoryTalk Batch Software Suite empowers you to standardize product
definitions, improve product quality, simplify product development, speed up
system deployment, and reduce implementation cost and risk.
FactoryTalk Batch Software Suite provides:
• Operators the view to effectively control the process
• Production the information to understand what’s happening
on the plant floor
• Recipe authors an environment to easily build and manage
product recipes
• Management the information needed to make sound business decisions
• Quality the information needed to improve the process and meet
compliance requirements
• Maintenance the tools required to quickly diagnose problems
• System designers the tools to support modular batch
automation using industry standards
• Engineers the ability to seamlessly connect the software to the
control system
FactoryTalk Batch Software Suite Version 11 benefits include:
Additional Capabilities (page 7)
• New intelligent recipe features
• Improved runtime user control
• Expanded data collection and reporting
• Enhanced material management capability
FactoryTalk Batch
Recipe Management and Procedural Control
FactoryTalk Batch provides efficient, predictable batch processing,
consistency between batches, and generation of event information
during batch runs. FactoryTalk Batch development tools enable you to
define equipment configurations and then build product recipes against
that defined equipment. These activities simplify the development of
each batch control system. FactoryTalk Batch brings all facets of batch
automation and process management together, providing the most
comprehensive batch management software available.
FactoryTalk Batch Recipe Editor
Define Your Product Recipes
In FactoryTalk Batch, the Batch Recipe Editor
is used to help you build recipes that define
the sequence of equipment actions in a batch
process. The Batch Recipe Editor provides
a simple way to configure, organize and
store recipe information according to the
ISA88.01 procedural model. Recipes are built
hierarchically and consist of procedures, unit
procedures, operations and phases. Recipes
also include descriptive information, formula
information, equipment requirements, and
the procedures used to make the batch.
FactoryTalk Batch Equipment Editor
Configure Your Equipment
FactoryTalk Batch leverages the ISA88.01 physical model hierarchy
to configure the physical equipment of your batching operations.
Using the graphical interface in the Batch Equipment Editor, you use
templates to create and maintain information about your process
equipment. Once you’ve defined the equipment, information is
available to all other FactoryTalk Batch components.
2
FactoryTalk Batch View
View and Control Your Batch Process
The standard human interface to our system
is the Batch View. Through the Batch View
options, you initiate recipes, control batches
and access all FactoryTalk information. You
can command and monitor batches from the
Batch List window, a table view, or from the
Sequential Function Charts of the selected
batch. The Batch View can be used stand-alone
or the individual Batch View components can be
added directly into container applications, such
as HMIs, web browsers or Visual Basic programs.
FactoryTalk Batch Server
Manage Your Batch Operations
The Batch Server is the engine that runs FactoryTalk Batch. It allocates
resources, supports system failure recovery, and provides communication
functions. It gathers and stores production information into the Batch
Event Journal for reporting and archiving. The Batch Server also supports
redundant storage. During runtime, the Batch Server is continuously
journaling all actions to one or multiple disk drives so that you can fully
recover data in the event of control system failure for system redundancy.
3
FactoryTalk eProcedure
Process Management for Manual Operations
FactoryTalk eProcedure automates manual procedures using an
interactive, web-based interface to sequence and document your
manufacturing operations. eProcedure provides the consistency
of automated controls in manual operations. Use eProcedure to
guide operators through manual activity or add links to production
documents such as operating procedures, material safety data sheets,
and equipment maintenance manuals.
Leverage an Interactive Web-Based Design
FactoryTalk eProcedure allows you to interact with
batches from remote computers using Microsoft®
Internet Explorer. With eProcedure, you no longer
need to write processing information on a piece of
paper for submission. You can enter the data directly
into your workstation. The data is directly stored in an
electronic batch record which can be downloaded into
your ODBC-compliant database for tracking.
Integrate Manual Work Instructions
into Your Automated Process
FactoryTalk eProcedure can be implemented in a
completely manual manufacturing facility or in a partially
automated facility by using all manual phases or a
combination of manual and automated phases within a
single recipe. Regardless of the state of automation, the
implementation process is the same. With eProcedure,
your paper-based operating procedures
are no longer required!
4
FactoryTalk Batch Material Manager
Material Management for Batch Operations
FactoryTalk Batch Material Manager brings just-in-time material
management to batch execution systems, allowing more effective
management of materials and recipes. FactoryTalk Batch Material
Manager provides plant-level material management and tracking,
and integrates with company-wide inventory management systems.
It complements ERP-level resource management by collecting the
detailed material and equipment tracking information needed for
optimizing your supply chain and e-business fulfillment.
FactoryTalk Batch Material Manager
Define your Inventory
The Material Editor provides an interface to help
you define material definitions, which consist of
material, lot, sublot, container, and storage location
data. During a batch run, information about available
containers can be presented to the operator for
selection decisions. After a batch is run, quantities
consumed or distributed are updated in the material
database for use in inventory tracking.
Integrate Material Management
into Your Product Definitions
Material-based recipes allow you to define
recipes in terms of materials used, not just by
plant equipment. A material-based recipe uses
material-enabled phases, which are configured in
the Equipment Editor and stored in the area model.
Material-enabled phases support the specification
of a material as a means to find appropriate
equipment and select that equipment in a recipe.
5
Software Suite: Additional Features
PhaseManager™
Preferred Integration
with Logix Controllers
FactoryTalk Batch integrates with Logix
PhaseManager, which embeds the ISA88
phase state model directly in a Logix-based
controller. PhaseManager provides a
structure to streamline the creation and
implementation of phase logic. The Phase
Logic Interface is now embedded directly in
the controller.
XML Support
Extend Your Connectivity
The Batch Equipment Editor can read,
import, and export XML area model files,
following the S88-S95 schemes. This makes it
possible for the Batch Equipment Editor to be
integrated into third-party editors or editing
procedures. The area model schema includes
signature templates and verification policies.
The Batch Recipe Editor can read and write
XML master recipes and the Batch Server
can read XML master recipes.
6
FactoryTalk Batch Simulator
Test Your Recipes
FactoryTalk Batch Archiver
Send Data to a Database
You can test recipes against plant
configurations without running them in
the plant using the Batch Simulator. You can
configure Batch Simulator to match a specific
project or application. During simulation
runtime, you can modify phases, change
phase states, and cut-over one phase at
a time, speeding the debugging process.
The Batch Archiver option collects data from
your electronic event journals and stores it
in an OBDC-compliant relational database,
such as SQL Server or Oracle®. Each batch
is recorded in a separate file that contains
a complete record of all activity for both
manual and automated workflow, including
time stamps, batch IDs, user names,
computer names and process cells.
Security and Auditing
Secure Your Environment
The security capabilities within FactoryTalk
Batch were designed with input from
major pharmaceutical clients and now
tightly integrate with FactoryTalk Security
and aspects of the FactoryTalk Services
Platform. The security levels can be
customized to meet the most demanding
requirements, such as the U.S. Food and Drug
administration (FDA) Good Manufacturing
Practice (GMP) regulations. Auditing provides
you with a detailed audit trail of user
changes to the area model and recipe data
made from the Batch Equipment and Recipe
Editors. These audit messages are forwarded
to FactoryTalk Diagnostics and FactoryTalk
Audit, and aspects of the FactoryTalk Services
Platform. FactoryTalk AssetCentre diagnostic
destination is also supported.
PC-Based Phases
Integrate Higher Level
Programming Languages
FactoryTalk Batch allows for Visual Basic
or Visual C++ PC-based phases that
communicate with the Batch server
without the use of a process-connected
device. PC-based phases can be used for a
variety of tasks, such as operator prompts,
timer, and calculations. By using PC-based
phases instead of phase logic, you can
decrease the memory required within
your process-connected devices.
Additional Batch Management Capabilities
Batch Reporting
With nine pre-configured web-based batch reports that leverage
data already being collected by FactoryTalk Batch, this reporting
solution can solve your most common batch reporting needs
including electronic batch records (EBR), track & trace genealogy,
and production exceptions. Since these reports are built on
open Microsoft Reporting Services technology, you can create
additional custom batch reports quickly and easily from these
existing open source templates.
Batch Reporting includes the following templates:
• Batch Reports - Batch Listing, Batch Summary,
Batch Detail
• Material Reports - Material Usage, Forward Tracking,
Backward Tracing
• Analysis Reports – Batch Execution, Duration Comparison,
Batch Exceptions
Integrated Batch Visualization
Seamlessly integrate batch control into the operator interface
with this solution which offers configurable, pre-engineered
FactoryTalk View graphics with embedded FactoryTalk Batch View
components. Since all graphics are built using standard
product features, you can quickly and easily create custom
views from existing screens.
Integrated Batch Visualization includes:
• Full Screen Graphics - Overview Batch Screen,
Line/Unit Batch Screen, eProcedure Batch Screens
• Pop-up Graphics - Instructions, Signatures,
Prompts, Add Batch
• Documented Batch API code - Batch List, Units List,
Recipe List, Add Batch, Batch Commands
Batch System Status
The Batch System Status application provides you with a new way to
take advantage of key information from the FactoryTalk Batch system.
This Microsoft Windows Service collects batch system details from the
batch server, organizes that data into two useful groupings (batch status,
unit status), and downloads the status information to the controllers. The
information can be used for process control decisions in code or displayed
to the operator through predefined FactoryTalk View HMI objects.
Key status data includes:
• Batch List Summaries, Recipe Header Detail,
Active Mode/State Status of Each Unit’s Batch.
• Batch and/or Unit Indication for Active Instructions,
Prompts, Signatures, & Failures
7
For More Information
To learn more on Rockwell Automation process solutions,
the FactoryTalk Batch Software Suite, and other add-on
capabilities visit these websites:
www.rockwellautomation.com/process
http://rockwellautomation.custhelp.com/
Search on answer ID 62366
Rockwell Automation, FactoryTalk, eProcedure, Allen-Bradley, and PhaseManager are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication FTALK-PP002B-EN-P – June 2010
Supersedes Publication FTALK-PP02A-EN-P – June 2007
Copyright © 2010 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.