Process Flow Analysis for Flexible Integrated Automation Jean

Process Flow Analysis for Flexible, Integrated Automation Jean Vieille Consultant – Industrial Production Control Strasbourg (France) MANUFACTURING IT Bologna, Italy March 01, 2001 1 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Agenda 1 - Centralized vs Distributed control l 2 - Automation Challenge within Production System l 3 - Flow Analysis Method l 4 - Objects collaboration l 5 - Practical use l 6 - Conclusion l 2 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

-1 Centralized vs Distributed Control 3 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

The Powerful Tyrex… l l Big brain Centralized design OK for steady / slow changing environment Shortcomings – Agility – Availability l Refer to first computerized systems 4 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

…vs Stupid Bird Limited intelligence l Mostly decentralized design l – Local decision making at feather level – Cope well with unexpected situations – Inherently adaptative structure 5 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

-2 Automation Challenge within Production System 6 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Automation Challenge Ideal automation Flexibility S 88 Manual Operation Darin Flemming Lou Pillai Capability Traditional Automation Complexity 7 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

S 88 in Production System Lifecycles Production Schedule S 88 : Resources S 88 : Recipe Product Enginnering S 88 : Equipment Procedural Elements Resources Engineering 8 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

From Goal to Labor Forecasting, Planning And Scheduling Process Control Definition Equipment Functional Capabilities Elementary Equipment Control The Goal: I know What/How To do Flying chirping Eating Walking Love. 9 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Scheduling hierarchy Business system MES systems SCADA systems ISA S 95 Process Control Equipment Control « Intelligent » Device ISA S 88 / IEC 61512 OPC IEC 61131 IEC 61499 ISA S 50 / IEC 61158 Fieldbus 10 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

-3 Flow Analysis Method 11 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Concurrent control of actuators Operator Control System Safety System Breakdown 12 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Material and Energy Flows Energy Sources A D B F E Material Sinks Material Sources C Energy Sinks 13 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

1. Identify Containers A D B F E Material Sinks Material Sources C 14 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

2. Identify realistic Paths A D B F E Material Sinks Material Sources C 15 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

3. Activate or Sequence Paths to Perform Process 1 4 A 3 2 D 3 B F E 5 Material Sinks Material Sources C 16 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Several paths simultaneously active Product / lot A Product / lot A 17 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

-4 Objects Collaboration 18 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

From Process to Device Control R 1: Process Control Function 1: Fill A Resource 1: Feeding Line Device 1 D 2 F 2: Fill B R 2: Tank A R 3: Tank B D 3 D 4 F 3: Transfer B-> C R 4: Transfer Line D 5 R 5: R 6: Tank C Tank D D 6 19 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Equipment level Control / Failure Control Discrepancy Limiting Actuator R 2 Measurement Fault R 1 20 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Cascading Process Cell Shutdown Process => Fault Allocating F 1 => Fault Adjacent R 3 => Fault Owning R 1 => Fault D 1 => Fault F 2 => OFF R 2 => OFF D 2 => OFF 21 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

-5 Practical use 22 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Limiting actuators – Flow Padlock R 1 & R 4 un-allocated (or allocated by another Function) R 1 A 1 Tank R 3 R 4 R 2 A 3 A 2 Function F 1 « Fill tank from R 2 » allocates R 2 & R 3 23 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Sanitary Status Padlock Upstream Resource Sanitary Status Downstream Resource Sanitary Status Clean Dirty Product X Product Y Clean Pass Locked Pass Dirty Pass Locked Product X Pass Locked Product Y Pass Locked Pass 24 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Equipment Control Project P&IDs Resources Breakdown & Id Process Control Definition Flows & Function Id Resources & Functions Design Generic Objects Definition OPERATION Operational Qualification System Design 25 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Conclusion Truly decentralized systems are comming l All levels well addressed l Flow Analysis helps for proper physical modelling l Outstanding benefits making OOD practical l New thinking processes, may lead to difficulties with Control Engineers l – Think Pipes rather than Bytes 26 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021

Information available at www. frenchbatchforum. org l World Batch Forum WG 4 « Flow Analysis » l – See above link – www. wbf. org l Powerpoint presentation on request – jean-vieille@usa. net 27 J. Vieille – “Process Flow Analysis for flexible, integrated automation” – Manufacturing IT – Bologna 19/12/2021