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Batch Controls
by
Randy Dwiggins, Invensys Inc.
On
October 2, twenty-nine members of the New Jersey and Central Jersey ISA turned
out at L'Affaire Restaurant in Mountainside for an excellent presentation on the
S-88 Batch Control standard by its current International Chairman, Lynn Craig. Prior to his last decade as SP-88 chairman and founder of
Manufacturing Automation Associates Inc., Mr. Craig was Corporate Manager of
Process Control for Rohm & Haas. In
that capacity and in his earlier work with Rohm & Haas, Mr. Craig's
extensive experience spanned development, justification, solution architect,
implementation, project and program manager, and champion for batch process
automation worldwide.
Rather
than present just another "how to" session on applying S-88, Mr. Craig
shared his personal insights into S-88's impact on achieving project buy-in and
success at all levels of the end user organization.
This "big picture" model was framed around the following
fundamental questions:
*
What is S-88? *
Why is it important?
* Who has to be involved?
*
What are the benefits?
* Where do they come from?
Mr.
Craig summarized the role of S-88 in batch control as providing a standard
terminology, simplifying modular control structures, and a separation of
equipment and process requirements. The
key consequences of this have been: (a) demystification of batch control for
users, operations management, and engineering staff outside of the control
community and (b) simplification of system validation and change control.
These, in turn, lead to better communication of user requirements,
stronger buy-in throughout the organization, and faster and more successful
deployment.
Mr.
Craig further pointed out how the proliferation of S88-consistent software has
dramatically improved the level of performance that can be achieved without
custom programming in the areas of recipe management, flexible manufacturing,
and electronic records. It was
noted, however, that all such software offerings currently fall short of S-88's
intent with regard to site and general recipes and nesting/collapsibility of
hierarchical recipe levels.
Particularly
emphasized was the need for early involvement with all stakeholders -- business
and manufacturing management, R&D, process, validation, maintenance, and
operations staff -- identifying and championing the benefits to each. Opportunities for batch automation abound, driven by such
factors as ever-tightening profit margins and quality requirements, more agile
production demands, and the impending retirement of a large segment of the
skilled labor force -- but they need to be identified, base-lined, and followed
up to demonstrate and insure achievement of the forecast benefits.
In
addition to the standard itself, Mr. Craig recommends the following papers and
links on this topic:
1.
Jeffrey Owen, “Evangelizing S88.01: Converting the Masses,”
World Batch Forum, 1997.
2.
Patrice Deschilder, “How Batch Control and Continuous Control Optimize
a Unit for Expandable Polystyrene,” World Batch Forum, 1998.
3.
Thomas Crowl, “S88.01 Concepts save Time and Money,” World Batch
Forum, 1998.
4.
Kandasamy Sakthivel, “Automation of a Lube Oil Additives and
Blending Plant Using S88.01-consistent Batch Software - A Case Study,” World
Batch Forum, 1999.
5.
Shawn Kerrick, “A Most Unusual Approach to Implementing S88 Recipes,”
World Batch Forum, 1999.
6.
Chinmoy Roy, “Implementing Automated Batch Control of a Biotechnology
Manufacturing Facility using S88.01 concepts – A Case Study,” World Batch
Forum, 2000.
7.
Todd Ray, “Batch Automation Project Increases Production,” World
Batch Forum, 2001.
8.
John W. W. Wood, Jr., “A DuPont Batch Automation Experience,” World
Batch Forum, 2001.
9.
http://www.findarticles.com/m0FVP/5_258/64148763/p1/article.jhtml
11.
http://www.chemicalprocessing.com/web_first/cp.nsf/Contents/8625688C005A2497862569A80056DBED?OpenDocument
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