Session Type: Paper
Paths(s): Management Executive Engineer
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.
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.
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).