Sustain.Ability. Chris Morse Batch Management Honeywell Users Group EMEA

Transcription

1 Sustain.Ability. Chris Morse Batch Management 2012 Honeywell Users Group EMEA 1

2 Groundbreaking Technology Shaping Batch Solutions New Experion Batch Manager Functionality Class based Master Recipes Recipe Builder Batch Application Services Server peer responder Migration from TotalPlant Batch (TPB) New 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

3 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

4 Experion Batch Manager Moving batch execution from here Batch Server TotalPlant Batch ACE or here or here C200E to here C300 4 Reduced Hardware & Lifecycle Costs

5 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 } New in Orion 5

6 Reducing Lifecycle Costs Operability Server Based Lifecycle Special skills Microsoft Alignment Management of Recipes Routine Change Single Point of Failure Batch Manager Lifecycle Operability Single Operator Environment Special Skills Single Engineer Environment Management of Recipes Class Based Recipes Routine Change Single point maintenance Single Point of Failure Bumpless Redundancy 6 Reduced Lifecycle Costs through Integrated Technology

7 Sustaining Knowledge -Master Recipes Recipe 1 Recipe 2 Recipe 3 Recipe n Recipe 1 Recipe 2 Recipe 3 Recipe n 7

8 Sustaining Knowledge -Master Recipes Recipe 1 Milk Recipe 1 Recipe 1 Mixer 2 Recipe 2 Recipe 3 Homogenise Homogenise Recipe 2 Recipe 3 Recipe 2 Mixer 2 Recipe 3 Mixer 21 Recipe n M1 M2 Recipe n Recipe n Recipe 1 Recipe 2 Recipe 3 Recipe 1 Recipe 2 Recipe 3 Recipe n F1 F2 Recipe n Class Based Recipes 8 Reducing Lifecycle Costs with Master Recipes

9 Business Integration - Batch Application Services MES/ERP: Master Recipe: GR1102 Batch ID: TD12345 Batch Size: 75% Initiator: 1.9 Kg Unit Mixer: M1 Master Recipe: GR1102 Batch ID: TD12345 Batch Size: 75% Initiator: 1.3 Kg Initiator: 1.9 Kg Unit Mixer: M1 MES Experion Server C300 C200E New in Orion 9 Improved Production Efficiency with ERP/MES Integration

10 Control Builder + Recipe Builder different roles Control Engineer Formulator 10 New Segregates Recipe Building role from Control Building role In Orion Reduce maintenance time & avoid errors RCMs & Master Recipes only built assigned & loaded in Recipe Builder Control Builder remains tool to do everything More efficient Recipe Management through Tool Segregation

11 Lifecycle Sustainability - Migration Legacy Batch Products can be migrated to EBM 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 TotalPlant Batch Experion Batch Manager 11

12 Experion TPB C200 to EBM Migration S88 Procedure/Unit Procedure/Operation Process Server TPB Servers Experion Stations C200(R) C200(R) C200E (R) S88 Phases S88 Procedure/Unit Procedure/Operation 12

13 TPB Migration to EBM C300 HPM Retained S88 Procedure/Unit Procedure/Operation GUS EST ESVT Batch Controller Plant Expansion TPB APP Warm Standby LCN C300(R) NIM (R) ENIM (R) HM LCN tag.parameter read/write EHPM (R) HPM (R) S88 Procedure/Unit Procedure/Operation S88 Phase level PMCL LCN tag.parameter read/write LCN tag.parameter read/write 13 Lifecycle Sustainability through Continuous Evolution

14 EBM Summary Experion Batch Manager Other Batch Products Your Business Benefit Reliable, deterministic Batch Execution in the controller Production reliability assured by full redundancy Fast, deterministic transitions between procedural elements for efficient batch cycle times Batch out of the box configured in familiar builder for engineering & operational efficiency No production interruptions - online modification for all batch functions Distributed batch execution in any controller Batch Execution at a server Production depends on warm restart or high availability server platform Longer transition times extending batch cycle times Additional package involving training & support Shutdown required for equipment & phase configuration Batch execution on a single server Improved production reliability Improved production reliability Increased plant throughput Reduced project & lifecycle costs Easy system modifications without interruption to production System scalability up and down 14

15 15 Questions?

16 Continue the Conversation Online #HUG12 Website HUG Live Flickr LinkedIn Facebook YouTube Honeywell Users Group 16