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Session Details

Business Integration: Taking it to the Next Level

7 November 9:15 a.m. - 10:45 a.m.

Session Type: Paper

Track: The Connected Enterprise

Paths(s): ManagementManagement   ExecutiveExecutive   EngineerEngineer   

In this paper session, industry experts will present a variety of new ideas to expand on the basics of systems integration and the connected enterprise in order to take it all to the next level. Emphasis in this session will be on the big picture of the connected enterprise and integrating manufacturing with the business to create a truly connected enterprise.

Paper(s):

Enterprise Batch Records

John Clemons BS, MA, MS, Maverick Technologies

Abstract:

Electronic Batch Records have proven to be a very effective way of managing the information associated with the execution of a batch and in analyzing batches, tracking batch history, and supporting lot genealogy.

Building on Electronic Batch Records is the idea of Enterprise Batch Records.  Enterprise Batch Records are designed to capture everything that happened to the finished product from the receiving dock to the shipping dock.  They capture materials, the lot genealogy, and everything else that went into manufacturing the product including equipment, labor, processes, maintenance, cleaning, quality, and safety.  Enterprise Batch Records capture everything that is needed to know exactly what happened in the manufacturing plant to get from the raw materials to the finished product.

Enterprise Batch Records support:  a) handling of a product retrieval or product recall, b) dealing with an equipment problem, and c) dealing with problems with a particular person working in the manufacturing area. They connect upstream to suppliers and downstream to customers, taking traceability to the next level and linking to the supply network and the distribution network, supporting supply chain traceability.

Enterprise Batch Records provide real-time or near-real-time access to manufacturing information providing the right information to the right people at the right time.  They also support continuous improvement activities and initiatives by providing historical analyses.

Integrating Continuous/Batch Production with the Business

Eric Heavin, Yokogawa Read Bio

Eric has worked at Yokogawa for over 6 years and has a total of 11 years experience in control system integration.  He has specialized in the application of MES and DCS layered products including Plant Information Management Systems and ERP interfacing as well as the development and deployment of custom applications.  Prior to his time with Yokogawa he worked for Bechtel Corporation supporting process control automation projects.

Eric graduated from the University of Nevada, Reno with a BS degree in Chemical Engineering.  He lives in Newnan, GA with his wife and three young children. In his free time he enjoys many outdoor activities including fishing, sporting clays, and cooking BBQ.

Abstract:

This paper describes how a global chemical company upgraded their antiquated automation and MES systems and moved to a modern architecture as part of the process.  The upgrade resulted in a leap in technology for both systems and will provide a framework for integrating additional production areas with the MES system over time. The chemical company’s thought process for selecting technology and architecture for this upgrade will be discussed.  Some of the issues involved were cyber-security and a desire for a standards based approach. 

The production process is a continuous blending, extrusion and rolling process that uses batches for grade changes and order tracking.  The MES and automation system had to reflect the continuous nature of the process and the speed required to maintain a backlog of control recipes and track batches to report order status.   The ISA-95 standard was selected as the overall framework for the MES and automation systems.  The implementation was based on B2MML (Business To Manufacturing Markup Language).  

Using Workflow to Achieve Business Integration

Jimmy Asher, Savingent Read Bio
Jimmy Asher, BSME is the Director of Product Strategy for Savigent Software. He has over 20 years of experience in manufacturing automation, systems integration and information management. His broad experiences, in both regulated and non-regulated industries, allow him to determine a path elevate information from the ‘shop floor' to a higher level for better business decisions and actions. Mr. Asher is both an ISA member and MESA member.

Abstract:

There are many issues facing manufacturers today: increasing regulation, a changing workforce, and unprecedented demands for operational performance. As these factors affect a business's bottom line; individual departments have sought out processes and systems to remove or mitigate the impact of their associated constraints. However typically, these processes or systems only address a particular departmental need, optimizing a portion of the enterprise at the expense of the whole. For example the quality department may seek out a Quality Management System (QMS) or the operations group may implement Performance Management System to track operational metrics.
 
As manufacturers evolve, a more holistic understanding is needed. It is the combination of the shared data from the all of these systems that delivers the information needed to react to business events or eventually predict future business performance. In the past, it was acceptable to arrive at this combined informational understanding via reports from each of the systems, which were passed between departmental managers. With market demand for decreased lead-times, this information must be shared in near real-time. Often times, manufacturers attempt to achieve this integration via costly, cumbersome point-to-point integrations limiting a manufacturer's ability to react to the dynamic market because of misunderstood, hardcoded logic.
 
A workflow based approach is an alternate method of business integration that allows greater flexibility. Workflows are the sequence of actions and events that define interactions between systems, equipment and people. Workflows can wrap existing purposed based systems allowing for easier integration while at the same time, remaining flexible for evolving business needs. Beyond this added flexibility, an approach will be identified that allows subject matter experts (SMEs) to create the integration without a separate IT effort. Workflow-based integration allows a purposed based system to be extended to maximize value in ways not possible with traditional business integration methods.