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Method for creating master recipes6834370
Abstract
A method is provided for automatically creating a set of master recipes from a general recipe using site information. Each master recipe includes a plurality of recipe segments. The general recipe includes a plurality of process actions. Each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material. Each master recipe is for use with a specific set of equipment in a process cell. Each process action has one or more corresponding recipe segments that implement the process action on the set of equipment. The general recipe describes how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material. The general recipe is independent of equipment. The method includes a first step of creating a list of recipe segments from the general recipe and the site information. The list of recipe segments includes each process action in the general recipe and a listing of all the corresponding recipe segments for that process action which can perform that process action in the process cell. The method includes a second step of creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.
Claims
What is claimed is:
1. A method for automatically creating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe segments, the general recipe comprising a plurality of process actions, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material, each master recipe for use with a specific set of equipment in a process cell, each process action implemented on the set of equipment by at least one recipe segment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the method comprising:
creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and for each process action a listing of corresponding recipe segments capable of performing that process action in process cell; and
creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.
2. A method as recited in claim 1, wherein the method does not require human interaction.
3. A method as recited in claim 1, wherein each of the master recipes is for use with a single one of the process cells.
4. A method as recited in claim 1, wherein each of the master recipes comprises a data file.
5. A method as recited in claim 4, wherein the data file is inked with at least one OLE object.
6. A method as recited in claim 1, wherein the master recipe comprises a procedure flow chart.
7. A method as recited in claim 1, wherein the process cell includes a batch control system interfacing the set of equipment, the batch control system is for controlling the operation of the set of equipment, and each of the master recipes is for use with the batch control system to control the set of equipment in the process cell.
8. A method as recited in claim 7, wherein:
the batch control system further includes a batch server in communication with at least one process connected device, the at least one process connected device interfacing the set of equipment, the at least one process connected device is for controlling the set of equipment, and the batch server is for controlling the process connected devices; and
the master recipe is for use with the batch server to control the process connected devices to manufacture the at least one product.
9. A method as recited in claim 7, wherein the batch control system has a process control application residing on the batch control system, the process control application is for operating on the batch control system, and each master recipe is for execution by the process control application to control the set of equipment.
10. A method as recited in claim 1, wherein each master recipe includes a formula and equipment requirements.
11. A method as recited in claim 1, wherein each master recipe includes at least one unit operation.
12. A method as recited in claim 11, wherein each unit operation includes a procedure, a formula, and equipment requirements.
13. A method as recited in claim 1, wherein each master recipe includes at least one unit procedure.
14. A method as recited in claim 13, wherein each unit procedure includes a procedure, a formula, and equipment requirements.
15. A method as recited in claim 1, wherein:
the recipe segments are organized into at least one segment path in the master recipe, the at least one segment path interconnected in a production path to form the master recipe;
the process actions are organized into at least one process branch in the general recipe, the at least one process branch interconnected in a dependency path to form the general recipe, each process branch having one or more corresponding segment paths which can perform the process branch on the set of equipment; and
the second step includes
a) dividing the general recipe into the dependency path and a collection of the at least one process branches,
b) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch,
c) using the collection of segment path series, the dependency path, and the site information to create a set of production paths, and
d) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
16. A method as recited in claim 15, wherein the at least one process branch comprises two or more process branches.
17. A method as recited in claim 16, wherein:
each process branch has a branch end, and
the dependency path includes at least one material join, the at least one material join connecting at least two branch ends.
18. A method as recited in claim 15, wherein:
the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another process branch; and
the at least one material comprises the at least one input material, the at least one product, or an intermediate material.
19. A method as recited in claim 1, wherein the general recipe comprises a data file.
20. A method as recited in claim 19, wherein the data file is linked with at least one OLE object.
21. A method as recited in claim 1, wherein the general recipe is comprises a process dependency chart.
22. A method as recited in claim 1, wherein the general recipe comprises a process sequence table.
23. A method as recited in claim 1, wherein the general recipe comprises a sequence function chart.
24. A method as recited in claim 1, wherein each general recipe includes a formula and equipment requirements.
25. A method as recited in claim 1, wherein each general recipe includes at least one process operation.
26. A method as recited in claim 25, wherein each process operation includes a procedure, a formula, and equipment requirements.
27. A method as recited in claim 1, wherein each general recipe includes at least one process stage.
28. A method as recited in claim 27, wherein each process stage includes a procedure, a formula, and equipment requirements.
29. A method as recited in claim 1, wherein the site information comprises a data file.
30. A method as recited in claim 1, wherein the site information comprises material flow information, recipe segment information, and equipment information.
31. A method as recited in claim 30, wherein the material flow information comprises information describing how material can flow between the set of equipment in the process cell.
32. A method as recited in claim 30, wherein the recipe segment information includes:
a listing of all the recipe segments available to perform the process actions in the process cell; and
a summary of the process action that each available recipe segment performs.
33. A method as recited in claim 32, wherein:
the set of equipment comprises units; and
the recipe segment information further includes a listing of the unit associated with each recipe segment and a listing of the at least one input material associated with each recipe segment.
34. A method as recited in claim 30, wherein the recipe segment information comprises operational limits associated with the process action that each recipe segment performs in the process cell.
35. A method as recited in claim 30, wherein the equipment information comprises equipment limits.
36. A method as recited in claim 1, wherein:
the set of equipment comprises units, each unit may have a unit start recipe segment or a unit end recipe segment associated with the unit, and
the equipment information comprises a list of the unit start recipe segments and the unit end recipe segments associated with each unit.
37. A method as recited in claim 1, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.
38. A method as recited in claim 37, wherein the data file is linked with at least one OLE object.
39. A method as recited in claim 1, wherein each recipe segment comprises a recipe phase.
40. A method as recited in claim 1, wherein each recipe segment includes recipe segment parameters.
41. A method as recited in claim 1, wherein each recipe segment includes a procedure, a formula, and equipment requirements.
42. A method as recited in claim 1, wherein each of the process actions comprises a data file.
43. A method as recited in claim 1, wherein each of the process actions includes process action parameters.
44. A method as recited in claim 1, wherein the at least one input material and the at least one product are bulk materials.
45. A method as recited in claim 15, wherein:
the site information includes optimization information;
and the second step includes using the optimization information to select at least one optional production path from the set of production patls and creating the set of master recipes from the at least one optimal production path.
46. A method as recited in claim 45, wherein the selection information includes cycle time information and the selection criteria is used to select the at least one optimal production path which will produce the at least one product in the least time.
47. A method as recited in claim 45, wherein the selection information includes equipment path information and the selection criteria is used to select the at least one optimal production path which will produce the at least one product in the least numbers of equipment.
48. A method as recited in claim 45, wherein the selection information includes material transfer cost information and the selection criteria is used to select the at least one optimal production path which will produce the at least one product with the least material transfer costs.
49. A method as recited in claim 1, wherein the set of equipment has an equipment layout and the general recipe is independent of equipment layout.
50. A method for automatically creating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe segments, the recipe segments organized into at least one segment path, the at least one segment path interconnected in a production path to form the master recipe, the general recipe comprising a plurality of process actions, the process actions organized into at least one process branch, the at least one process branch interconnected in a dependency path to form the general recipe, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material, each master recipe for use with a specific set of equipment in a process cell, each process action implemented on the set of equipment by at least one recipe segment, each process branch having one or more segment paths which perform the process branch on the set of equipment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the site information including recipe segment information, material flow information, and equipment information, the method including the steps of:
a) creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and for each process action a listers of corresponding recipe segments capable of performing that process action in the process cell;
b) dividing the general recipe into the dependency path and a collection of the at least one process branches;
c) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch;
d) using the collection of segment path series, the dependency path, and the site information to create a set of production paths; and
e) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
51. A method as recited in claim 50, wherein the method does not require human intervention.
52. A method as recited in claim 50, wherein each master recipe is for use with a single process cell.
53. A method as recited in lain 50, wherein each master recipe comprises a data file.
54. A method as recited in claim 53, wherein the data file is linked with at least one OLE object.
55. A method as recited in claim 50, wherein each master recipe comprises a procedure flow chart.
56. A method as recited in claim 50, wherein the process cell includes a batch control system interfacing the set of equipment, the batch control system is for controlling the operation of the set of equipment, and each master recipe is for use with the batch control system to control the set of equipment in the process cell.
57. A method as recited in clam 50, wherein each master recipe includes at least one unit operation.
58. A method as recited in claim 50, wherein each master recipe includes at least one unit procedure.
59. A method as recited in claim 50, wherein the at least one process branch comprises two or more process branches.
60. A method as recited in claim 59, wherein: each process branch has a branch end, and
the dependency path includes at least one material join, the at least one material join connecting at least two branch ends 61.
61. A method as recited in claim 50, wherein:
the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another p process branch; and
the at least one material comprises the at least one input material, the at least one product, or an intermediate material.
62. A method as recited in claim 50, wherein the general recipe comprises a data file.
63. A method as recited in claim 50, wherein the data file is linked with at least one OLE object.
64. A method as recited in claim 50, wherein the general recipe comprises a process dependency chart.
65. A method as recited in claim 50, wherein the general recipe comprises a process sequence table.
66. A method as recited in claim 50, wherein the general recipe comprises a sequence function chart.
67. A method as recited in claim 50, wherein each general recipe includes at least one process operation.
68. A method as recited in claim 50, wherein each general recipe includes at least one process stage.
69. A method as recited in claim 50, wherein the site information comprises a data file.
70. A method as recited in claim 50, wherein the recipe segment information includes:
a listing of all the recipe segments available to perform the process actions in the process cell; and
a summary of the process action that each available recipe segment performs.
71. A method as recited in claim 50, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.
72. A method as recited in claim 71, wherein the data file is inked with at least one OLE object.
73. A method as recited in claim 50, wherein each recipe segment comprises a recipe phase.
74. A method as recited in claim 50, wherein each process action comprises a data file.
75. A method as recited in claim 50, wherein:
the site information includes optimization formation; and
the method includes using the optimization information to select at least one optimal production path from the set of production paths and creating the set of master recipes,from the at least one optimal production path.
76. A method for automatically creating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe segments, the recipe segments organized into at least one segment path, the at least one segment path interconnected in a production path to form the master recipe, the general recipe comprising a plurality of process actions, the process actions organized into at least one process branch, the at least one process branch interconnected in a dependency path to form the general recipe, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material, each master recipe for use with a specific set of equipment in a process cell, each process action implemented on the set of equipment by at least one recipe segment, each process branch having one or more segment paths which perform the process branch on the set of equipment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the site information including recipe segment information, material flow information and equipment information, the method including the steps of
a) creating a list of recipe segments from the general recipe and the recipe segment information, the list of recipe segments including each process action in the general recipe and for each process action a listing of corresponding recipe segments capable of performing that process action in the process cell;
b) dividing the general recipe into the dependency path and a collection of the at least one process branches;
c) using the list of recipe segments and the material flow information to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment pat series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch;
d) using the collection of segment path series, the dependency path, and the material flow information to create a set of production paths; and
e) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
77. A method as recited in claim 76, wherein the method does not require human intervention.
78. A method as recited in claim 76, wherein each master recipe is for use with a single process cell.
79. A method as recited in claim 76, wherein each master recipe comprises a data file.
80. A method as recited in claim 79, wherein the data file is linked with at least one OLE object.
81. A method as recited in claim 76, wherein each master recipe comprises a procedure flow chart.
82. A method as recited in claim 76, wherein the process cell includes a batch control system interfacing the set of equipment, the bath control system is for controlling the operation of the set of equipment, and each master recipe Is for use with the batch control system to control the set of equipment in the process cell.
83. A method as recited in claim 76, wherein each master recipe includes at least one unit operation.
84. A method as recited in claim 76, wherein each master recipe includes at least one unit procedure.
85. A method as recited in claim 76, wherein the at least one process branch comprises two or more process branches.
86. A method as recited in claim 85, wherein:
each process branch has a branch end, and
the dependency path includes at least one material join, the at least one material join connecting at least two branch ends.
87. A method as recited in claim 76, wherein:
the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another process branch; and
the at least one material comprises the at least one input material, the at least one product, or an intermediate material.
88. A method as recited in claim 76, wherein the general recipe comprises a data file.
89. A method as recited in claim 88, wherein the data file is linked with at least one OLE object.
90. A method as recited in claim 76, wherein the general recipe comprises a process dependency chart.
91. A method as recited in clam 76, wherein the general recipe comprises a process sequence table.
92. A method as recited in claim 76, wherein the general recipe comprises a sequence function chart.
93. A method as recited in claim 76, wherein each general recipe includes at least one process operation.
94. A method as recited in claim 76, wherein each general recipe includes at least one process stage.
95. A method as recited in claim 76, wherein the site information comprises a data file.
96. A method as recited in claim 76, wherein the recipe segment information includes:
a listing of all the recipe segments available to perform the process actions in the process cell; and
a summary of the process action that each available recipe segment performs.
97. A method as recited in claim 76, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.
98. A method as recited in claim 97, wherein the data file is linked with at least one OLE object.
99. A method as recited in claim 76, wherein each recipe segment comprises a recipe phase.
100. A method as recited in claim 76, wherein each of the process actions comprises a data file.
101. A method as recited in claim 76, wherein:
the site information includes optimization information; and
the method includes using the optimization information to select at least one optimal production path from the set of production paths and creating the set of master recipes from the at least one optimal production path.
102. A method for automatically seating a set of master recipes from a general recipe using site information, each master recipe comprising a plurality of recipe phases, the general recipe comprising a plurality of process actions, each master recipe for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material by using recipe segments, the recipe segments comprising at least one recipe phase, each process action being performed by one recipe segment, each master recipe for use with a specific set of equipment in a process cell, each process action having one or more corresponding recipe segments that implement the process action on the set of equipment, the general recipe for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material, the general recipe being independent of equipment, the method comprising:
a first step of creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and for each process action a listing of corresponding recipe segments capable of performing that process action in the process cell; and
a second step of creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.
103. A method as recited in claim 102, wherein the method does not require human intervention.
104. A method as recited i claim 102, wherein each master recipe is for use with a single process cell.
105. A method as recited in claim 102, wherein each master recipe comprises a data file.
106. A method as recited in claim 105, wherein the data file is linked with at least one OLE object.
107. A method as recited in claim 102, wherein each master recipe comprises a procedure flow chart.
108. A method as recited in claim 102, wherein the process cell includes a batch control system interfacing the set of equipment, the batch control system is for controlling the operation of the set of equipment, and each master recipe is for use with the batch control system to control the set of equipment in the process cell.
109. A method as recited in claim 102, wherein each master recipe includes at least one unit operation.
110. A method as recited in claim 102, wherein each master recipe includes at least one unit procedure.
111. A method as recited in claim 102, wherein:
the recipe segments are organized into at least one segment path in the master recipe, the at least one segment path interconnected in a production path to form the master recipe,
the process actions organized into at least one process branch in the general recipe, the at least one process branch interconnected in a dependency path to form the general recipe, each process branch having one or more corresponding segment paths which can perform the process branch on the set of equipment, and
the second step includes
a) dividing the general recipe into the dependency path and a collection of the at least one process branches,
b) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch, the segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch,
c) using the collection of segment path series, the dependency path, and the site information to create a set of 5 production paths, and
d) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
112. A method as recited in claim 111, wherein the at least one process branch comprises two or more process branches.
113. A method as recited in claim 112, wherein:
each process branch has a branch end, and
the dependency path includes at least one material join, the at least one material join connecting at least two branch ends.
114. A method as recited in claim 102, wherein:
the at least one segment path is for processing at least one material separately without a material join from another segment path and the at least one process branch is for describing how to process the at least one material separately without a material join from another process brand; and
the at least one material comprises the at least one input material, the at least one product, or an intermediate material.
115. A method as recited in claim 102, wherein the general recipe comprises a data file.
116. A method as recited in claim 115, wherein the data file is linked with at least one OLE object.
117. A method as recited in claim 102, wherein the general recipe comprises a process dependency chart.
118. A method as recited in claim 102, wherein the general recipe comprises a process sequence table.
119. A method as recited in claim 102, wherein the general recipe comprises a sequence function chart.
120. A method as recited in clam 102, wherein each general recipe includes at least one process operation.
121. A method as recited in claim 102, wherein each general recipe includes at least one process stage.
122. A method as recited in claim 102, wherein the site information comprises a data file.
123. A method as recited in claim 102, wherein the recipe segment information includes:
a listing of all the recipe segments available to perform the process actions in the process cell; and
a sublunary of the process action that each available recipe segment performs.
124. A method as reacted in claim 102, wherein each recipe segment comprises a data file for performing the corresponding process action on the set of equipment.
125. A method as recited in claim 124, wherein the data file is linked with at least one OLE object.
126. A method as recited in claim 102, wherein each process action comprises a data file.
127. A method as recited in claim 102, wherein:
the site information includes optimization information; and
the second step included using the optimization information to select at least one optimal production from the set of production paths and creating the set of master recipes from the at least one optimal production path.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods for creating master recipes for manufacturing products with process equipment in a plant with a plant-level batch control computer system. More specifically it relates to methods for creating master recipes automatically or semi-automatically by converting them from general recipes which are independent of equipment.
2. Description of the Related Art
The process industry is the segment of industry which handles bulk materials, such as chemicals, food products, bulk polymeric materials, fuels, pharmaceuticals, etc., by processing input materials in a bulk manner to change their physical or chemical state to manufacture products. Industrial processes within this industry often can be segregated into one of three categories, i.e., continuous operations, batch operations and discrete operations. Batch operations are required when the products being manufactured, for example, either: (1) do not justify a dedicated, continuous operation, (2) are not capable of being produced by a continuous operation, (3) pose an unreasonable risk if the batch is fouled or lost, etc. Batch type operations of the second category (i.e., those which are incapable of continuous operation) which do not fall within the first category (do justify a dedicated continuous operation) typically will have a dedicated production line, which operates in a semi-continuous manner. Products, which fall into the first category, create a unique, and very significant sector in the process industry. The term "batch process" typically refers to processes in the first category (processes which do not justify a continuous operation).
Process plants, which perform batch processes, deal with a variety of unique issues. Each plant, or manufacturing site, will typically have manufacturing areas with one or more subordinate process cells. The process cells contain process equipment arranged in a manner, which will allow them to manufacture a variety of products. Very often these process cells will perform as independent or contract manufacturing facilities, manufacturing different products on a regular basis depending upon customer or company needs. The process cells will be designed to allow materials to flow in a variety of flow paths within the cell. The equipment within these cells is typically selected to allow the plant to perform a variety of different process operations, such as mixing, heating, cooling, filtering, distilling, crystallizing, etc. The combination of the variable flow paths between the equipment and the variety of process operations available within the cell provide the flexibility to manufacture a large variety of batch products to different procedures. This allows the plant to maximize the utilization of its resources, thereby minimizing the cost to produce the products.
Products manufactured by batch processes are no different than any other product. They require a detailed procedure to be performed by the equipment within the process cell in order to manufacture the product. These procedures, by their very nature, must be specific to the process cell to assure they are executed accurately. Most of the process cells used today are either partially, or fully automated. In the case of automated cells, the procedure typically will not even run if the procedure is not absolutely specific. This means that a different procedure is required for every process cell. In fact, a single process cell is often able to produce the same product with a variety of different procedures, in many cases using different equipment and material routings within the process cell.
Companies that specialize in batch processes in the process industry often have a large number of process cells, usually with a variety of different configurations. A company may have multiple sites, or plants, each site having multiple process cells. The sites may have different operating standards. For example, the process control systems often include process controllers interfacing the equipment and controlling the operation of the equipment directly, and computer systems in communication with the process controllers. The computer systems allow operators to monitor and supervise the process by indirectly interfacing the process controllers through the computer system. Different sites may have different process controllers operating on different control software and different computer systems operating on different supervisory software. For example, one site may have a WINDOWS.RTM. based operating system and another may have a UNIX-based operating system. There are also many different process controllers in use. Commonly used process controllers include Allen Bradley PLC 5, Allen Bradley PCL 5/250, Allen Bradley SLC 5/04, Siemens 505, Siemens S5, Siemens S7/PCS7, Siemens Teleperm M, Honeywell TPS 100, Honeywell PlantScape, Honeywell IPC 620, Hartman & Braun Freelance 2000, Fischer Provox, Modicon Quantum, and Moore APACS.
Differences between process cells and between company sites combined with the discontinuous nature of batch processes more often than not result in a vary large number of procedures to create the same product throughout the company. There are also different kinds of procedures associated with any one product. The need to disseminate the general procedure for making any one product throughout the company creates the need for procedures, which are not equipment specific, and do not include the details associated with the process cell. These procedures are process specific and provide the necessary detail to communicate how to manufacture the product independent of equipment. They are typically normalized relative to quantity of product (i.e., percentages, lb. per lb., etc.). Other needs, for example, resource planning and scheduling needs such as are required by production controllers and enterprise resource planning systems, define other types of procedures which typically are even more general than those previously described. An example of this type of procedure is a simple bill of materials and general operations.
It is generally recognized in the industry that there are four major categories of procedure types for batch processes. These procedure types are defined by the Instrument Society of America (ISA) in ISA standard S88.01, released in October of 1995. These four procedural categories are given in ISA S88.01 as the "general recipe," the "site recipe," the "master recipe," and the "control recipe." The definitions of these categories of procedures as given in ISA S88.01 follow. The ISA S88.01 definition of "recipe" is also given for reference purposes.
General Recipe--A type of recipe that expresses equipment and site independent processing requirements.
Site Recipe--A type of recipe that is site specific.
Master Recipe--A type of recipe that accounts for equipment capabilities and may include cell-specific information.
Control Recipe--A type of recipe, which, through its execution, defines the manufacture of a single batch of specific product.
Recipe--The necessary set of information that uniquely defines the production requirements for a specific product.
The term "master recipe" as used herein refers to the equipment specific procedure for manufacturing a product, or group of products, from one or more input materials in a process cell using a specific set of equipment with a specific equipment layout. The master recipes are generally quantity independent and represent material quantity requirements normalized to the amount of product being produced. The term master recipe as used herein also includes quantity-specific recipes such as control recipes, as described in more detail later. The term specific set of equipment means the same type and numbers of equipment, which can perform the same processes, requiring the same commands from the supervisory computer system to perform these processes.
The term specific equipment layout means the equipment items are interconnected to allow materials to flow between the different pieces of equipment in the same manner, so that materials may be routed to and from equipment in the same manner with the same control commands from the supervisory computer system.
The term "general recipe" as used herein means the equipment independent procedure for manufacturing a product or group of products from one or more input materials. As with the master recipe, the general recipes are typically quantity independent. The definition of term general recipe as used herein includes both the definition of the term general recipe and the term site recipe as given in ISA S88.01. The term general recipe as used herein may or may not include certain site specific information that is independent of equipment, such as local language (i.e., English, French, German, etc.), engineering units (i.e., metric vs. British system), site specific operating instructions, safety and regulatory requirements, etc.
The term "control recipe" as used herein conforms to the ISA S88.01 definition of control recipe, and means the specific recipe for manufacturing a specific lot of product in a specific quantity from specific quantities of input materials. The control recipe is the recipe required to "push the button" on the control system and make the product. Generally speaking, the master recipe and the control recipe as defined in ISA S88.01 are very closely related. Each control recipe is generally created from a quantity independent master recipe prior to production of the product in the process cell, often immediately prior to production. The additional information required to create the control recipe from the quantity independent master recipe will vary from product to product and site to site. The additional information generally includes the quantity of product to be manufactured. This may be the only information required to create the control recipe from the quantity independent master recipe, or the information may further include, for example, identification of the input material lots to be used, time stamps for the actual time of manufacture, identification of the actual product lot to be produced, and other lot and batch specific information that is required to manufacture a specific lot of product in a specific quantity.
The control recipe may be created from the quantity independent master recipe automatically without human intervention, semi-automatically with only slight human intervention, or manually by having an operator enter the required information directly into a copy of the quantity independent master recipe or, Alternatively, an old control recipe on file. This will vary from company to company and from site to site depending upon such things as the company standards and the process control system available at the location of manufacture. Typically, the conversion of quantity independent master recipes to control recipes is a relatively straightforward process. The master recipe and the control recipe as defined in ISA S88.01 are very similar. Therefore, the term master recipe as used herein includes both the master and control recipes as defined in ISA S88.01. The conversion of general recipes to master recipes is not a trivial process, however. This effort requires complete knowledge of the set of equipment (such as its processing capabilities and constraints) and the equipment layout in the process cell for which the product is targeted to be manufactured. Process cells often can support many procedures due to the multitude of possible permutations of the equipment included in the set of equipment, which may be used to manufacture the product. This further complicates the process. In addition, typically there is not a one to one relationship between process operations, which are to be performed, and the equipment operations available to perform them. ISA S88.01 identifies the two different models required to describe the general and the master recipe as the process model and the procedural control model respectively. The process model defines the equipment independent procedure for manufacturing the products, or the general recipe, in terms of process actions. Process actions are the smallest element, which can be performed in the process model. "Process actions" are simple actions to be performed on the materials, such as charge material, heat, mix, discharge material, etc. The procedural control model defines the equipment specific procedure for manufacturing the products, or the master recipe, in terms of recipe phases. "Recipe phases" are the smallest element of the procedural control model that can be performed on the equipment with the master or control recipe. Unfortunately, there is rarely a one-to-one relationship between the elements of the two models. It often takes multiple recipe phases to perform one process action. The simple process action of charge 0.2 lb. per lb. product of material A into unit one may require the recipe phases corresponding to open the exit valve, evacuate the vessel, verify the vessel weight indicates empty, close the exit valve, monitor the vessel weight, activate inlet pump A at 30 RPM, open inlet valve A, when vessel weight increase equals 200 lbs close inlet valve A, deactivate inlet pump A. Historically master recipes have generally been created manually from the general recipes or, Alternatively, from other master recipes for products with similar manufacturing procedures. Due to the complex nature of the task, the creation and verification of master recipes from corresponding general recipes has historically been a costly and time-consuming task. Additionally, manual creation and verification of master recipes is not very reliable and is prone to error. It usually requires one or more pilot or trial runs with the new master recipe to validate the recipe. The material used for this validation often becomes scrap.
The time consuming nature of manually creating and maintaining master recipes often means that the optimization of master recipes relative to parameters such as cost, production time, or even production location, is not performed. Companies are generally forced to have a restricted number of non-optimized master recipes with which to manufacture their products.
OBJECTS OF THE INVENTION
Accordingly, an object of the present invention is to provide a method for creating master recipes quickly relative to commercially known methods.
Another object of the present invention is to provide a method for creating master recipes with minimal human intervention.
Another object of the present invention is to provide a method for creating master recipes directly from a general recipe.
Another object of the present invention is to provide a method for creating master recipes reliably.
Another object of the present invention is to provide a method for creating master recipes that allows for selection of an optimum master recipe.
Additional objects and advantages of the invention will be set forth in the description, which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations pointed out in the appended claims.
SUMMARY OF THE INVENTION
To achieve the foregoing objects, and in accordance with the purposes of the invention as embodied and broadly described in this document, in accordance with one aspect of the invention a method is provided for automatically creating a set of master recipes from a general recipe using site information. Each master recipe comprises a plurality of recipe segments and the general recipe comprising a plurality of process actions. Each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material. Each master recipe is for use with a specific set of equipment in a process cell. Each process action has one or more corresponding recipe segments that implement the process action on the set of equipment. The general recipe describes how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material. The general recipe is independent of equipment.
The method according to this aspect of the invention includes a first step of creating a list of recipe segments from the general recipe and the site information. The list of recipe segments includes each process action in the general recipe and a listing of all the corresponding recipe segments for that process action which can perform that process action in the process cell.
The method includes a second step of creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.
In the preferred embodiments, the method does not require human interaction or intervention. It is carried out automatically or semi-automatically. Each master recipe is for use with a single process cell. Alternatively, each master recipe may be for use with a group or class of process cells with the same equipment configuration. Each master recipe includes one or more a data files. The data files are preferably linked with at least one OLE object. The master recipe preferably is depicted as a procedure flow chart.
In the preferred applications, the process cell includes a batch control system interfacing the set of equipment. The batch control system is for controlling the operation of the set of equipment. Each master recipe is for use with the batch control system to control the set of equipment in the process cell.
The batch control system further includes a batch server in communication with at least one process connected device. The process connected devices interface the set of equipment and are for controlling the set of equipment. The batch server is for controlling the process connected devices, and the master recipe is for use with the batch server to control the process connected devices to manufacture the at least one product.
Preferably, the batch control system has a process control application residing on the batch control system. The process control application is for operating on the batch control system and each master recipe is for execution by the process control application to control the set of equipment.
In the preferred embodiments in accordance with this aspect of the invention, each master recipe includes a formula and equipment requirements. Each master recipe may include at least one unit operation and each unit operation may include a procedure, a formula, and equipment requirements. In addition, each master recipe may further include at least one unit procedure and each unit procedure may include a procedure, a formula, and equipment requirements.
Further in accordance with the preferred embodiments of this aspect of the invention, the recipe segments are organized into at least one segment path in the master recipe. The segment paths are interconnected in a production path to form the master recipe. The process actions are organized into at least one process branch in the general recipe. The process branches are interconnected in a dependency path to form the general recipe. Each process branch has one or more corresponding segment paths, which can perform the process branch on the set of equipment. The second step preferably includes: a) dividing the general recipe into the dependency path and a collection of the at least one process branches; and b) using the list of recipe segments to analyze each process branch in the collection of the at least one process branches to create a segment path series for the process branch. The segment path series includes all the segment paths corresponding to the process branch. The analysis results in a collection of segment path series corresponding to the collection of the at least one process branch. This second step also includes: c) using the collection of segment path series, the dependency path, and the site information to create a set of production paths; and d) using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
In the preferred versions, the at least one process branch typically includes two or more process branches. Each process branch has a branch end. The dependency path often includes at least one material join. Each material join connects at least two branch ends. The segment paths are for processing at least one material separately without a material join from another segment path. The process branches are for describing how to process the at least one material separately without a material join from another process branch. The at least one material is an input material, a product, or an intermediate material.
In the preferred embodiments, the general recipe includes one or more data files. The data files are linked with at least one OLE object. The general recipe preferably is depicted by one or more process dependency charts. The general recipe is preferably represented by one or more process sequence tables. Alternatively, but preferably, the general recipe is depicted by one or more sequence function charts.
Preferably, each general recipe includes a formula and equipment requirements. Each general recipe may include at least one process operation and each process operation may further include a procedure, a formula, and equipment requirements. In addition, each general recipe may include at least one process stage. Each process stage may further include a procedure, a formula, and equipment requirements.
Preferably, the site information includes one or more data files. The site information includes material flow information, recipe segment information, and equipment information. The material flow information includes information describing how material can flow between the equipment in the process cell. The recipe segment information includes a listing of all the recipe segments available to perform the process actions in the process cell, and a summary of the process action that each available recipe segment performs. Preferably, the set of equipment includes units and the recipe segment information further includes a listing of the unit associated with each recipe segment and a listing of the at least one input material associated with each recipe segment. The recipe segment information includes operational limits associated with the process action that each recipe segment performs in the process cell. The equipment information includes equipment limits. The set of equipment includes units, and each unit may have a unit start recipe segment or a unit end recipe segment associated with the unit, and the equipment information includes a list of the unit start recipe segments and the unit end recipe segments associated with each unit.
In the preferred embodiments in accordance with this aspect of the invention, each recipe segment includes one or more data files for performing the corresponding process action on the set of equipment, and the data files are linked with at least one OLE object. Each recipe segment includes one or more recipe phases. Each recipe segment includes recipe segment parameters. Preferably, each recipe segment includes a procedure, a formula, and equipment requirements.
In the preferred versions, each process action includes one or more data files. Each process action includes process action parameters.
In the preferred versions of the method in accordance with this aspect of the invention, the at least one input material and the at least one product are bulk materials.
Further in accordance with the preferred versions of this aspect of the invention, the site information includes optimization information. The second step of the method includes using the optimization information to select at least optimal production path from the set of production paths to create the set of master recipes from the optimal production paths. The selection information may be cycle time information. The selection criteria may be used to select the optimal production paths, which will produce the product in the least time. Alternatively, the selection information may be equipment path information. The selection criteria may be used to select the optimal production paths, which will produce the product in the least numbers of equipment. The selection information may be material transfer cost information. In this case, the selection criteria may be used to select the optimal production paths, which will produce the product with the least material transfer costs.
In the preferred embodiments in accordance with this aspect of the invention, the set of equipment has an equipment layout and the general recipe is independent of equipment layout.
In accordance with another aspect of the invention, a method is provided for automatically creating a set of master recipes from a general recipe using site information. Each master recipe comprises a plurality of recipe segments. The recipe segments are organized into at least one segment path. The segment paths are interconnected in a production path to form the master recipe. The general recipe comprises a plurality of process actions. The process actions are organized into at least one process branch. The process branches are interconnected in a dependency path to form the general recipe.
Each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material. Each master recipe for use with a specific set of equipment in a process cell. Each process action has one or more corresponding recipe segments that implement the process action on the set of equipment. Each process branch has one or more segment paths, which perform the process branch on the set of equipment.
The general recipe describes how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material. The general recipe is independent of equipment. The site information includes recipe segment information, material flow information, and equipment information. The method includes the step of creating a list of recipe segments from the general recipe and the site information. The list of recipe segments includes each process action in the general recipe and a listing of all the corresponding recipe segments for that process action which can perform that process action in the process cell. This method also includes the steps of dividing the general recipe into the dependency path and a collection of the at least one process branches, and using the list of recipe segments to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch. The segment path series including all the segment paths corresponding to the process branch, the analysis resulting in a collection of segment path series corresponding to the collection of the at least one process branch, a step of using the collection of segment path series, the dependency path, and the site information to create a set of production paths, and a step of using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
In the preferred embodiments in accordance with this aspect of the invention, the method does not require human interaction. Each master recipe is for use with a single process cell. Each master recipe includes one or more a data files. The data file preferably is linked with at least one OLE object. The master recipe is preferably depicted by a procedure flow chart.
In the preferred embodiments, the process cell includes a batch control system interfacing the set of equipment. The batch control system is for controlling the operation of the set of equipment and each master recipe is for use with the batch control system to control the set of equipment in the process cell. Each master recipe may include at least one unit operation. Each master recipe may further include at least one unit procedure.
The at least one process branch typically is two or more process branches. Each process branch has a branch end. The dependency path includes at least one material join the material joins connect at least two branch ends. The segment paths are for processing at least one material separately without a material join from another segment path. The process branches describe how to process the at least one material separately without a material join from another process branch. The at least one material is an input material, a product, or an intermediate material.
In the preferred embodiments in accordance with this aspect of the invention, the general recipe includes one or more a data files. The data files are linked with at least one OLE object.
One or more process dependency charts preferably depict the general recipe. The general recipe preferably is depicted by one or more a process sequence tables. Alternatively, but preferably, the general recipe is depicted by one or more sequence function charts. Each general recipe may include at least one process operation. Each general recipe may also include at least one process stage.
In the preferred embodiments, the site information includes one or more a data files. The recipe segment information includes a listing of all the recipe segments available to perform the process actions in the process cell and a summary of the process action that each available recipe segment performs.
Each recipe segment includes one or more data files for performing the corresponding process action on the set of equipment. The data files are preferably linked with at least one OLE object. Each recipe segment includes one or more recipe phases. Each process action includes one or more a data files.
In the preferred embodiments in accordance with this aspect of the invention, the site information includes optimization information. The method includes using the optimization information to select at least one optimal production path from the set of production paths to create the set of master recipes from the optimal production paths.
In accordance with another aspect of the invention, a method is provided for automatically creating a set of master recipes from a general recipe using site information. Each master recipe comprising a plurality of recipe segments. The recipe segments organized into at least one segment path. The segment paths interconnected in a production path to form the master recipe. The general recipe comprising a plurality of process actions. The process actions organized into at least one process branch. The process branches interconnected in a dependency path to form the general recipe.
Each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material. Each master recipe is for use with a specific set of equipment in a process cell. Each process action has one or more corresponding recipe segments that implement the process action on the set of equipment. Each process branch has one or more segment paths, which perform the process branch on the set of equipment.
The general recipe describes how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material. The general recipe is independent of equipment. The site information includes recipe segment information, material flow information, and equipment information. The method includes the step of creating a list of recipe segments from the general recipe and the recipe segment information. The list of recipe segments includes each process action in the general recipe and a listing of all the corresponding recipe segments for that process action which can perform that process action in the process cell. The method also includes the step of dividing the general recipe into the dependency path and a collection of the at least one process branches, and the step of using the list of recipe segments and the material flow information to analyze each process branch in the collection of the at least one process branches and create a segment path series for the process branch. The segment path series includes all the segment paths corresponding to the process branch. The analysis results in a collection of segment path series corresponding to the collection of process branches. The method also includes the step of using the collection of segment path series, the dependency path, and the material flow information to create a set of production paths, and the step of using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
In the preferred embodiments in accordance with this aspect of the invention, the method does not require human interaction. Each master recipe is for use with a single process cell. Each master recipe includes one or more a data files. The data file preferably is linked with at least one OLE object. The master recipe is preferably depicted by a procedure flow chart.
In the preferred embodiments, the process cell includes a batch control system interfacing the set of equipment. The batch control system is for controlling the operation of the set of equipment, and each master recipe is for use with the batch control system to control the set of equipment in the process cell. Each master recipe may include at least one unit operation. Each master recipe may further include at least one unit procedure.
The at least one process branch typically is or includes two or more process branches. Each process branch has a branch end. The dependency path includes at least one material join. The material joins connect at least two branch ends. The segment paths are for processing at least one material separately without a material join from another segment path. The process branches describe how to process the at least one material separately without a material join from another process branch. The at least one material is an input material, a product, or an intermediate material.
In the preferred embodiments in accordance with this aspect of the invention, the general recipe includes one or more data files. The data files are linked with at least one OLE object. The general recipe preferably is depicted by one or more process dependency charts. The general recipe preferably is depicted by one or more process sequence tables. Alternatively, but preferably, the general recipe is depicted by one or more sequence function charts. Each general recipe may include at least one process operation. Each general recipe may also include at least one process stage.
In the preferred embodiments, the site information includes one or more data files. The recipe segment information includes a listing of all the recipe segments available to perform the process actions in the process cell and a summary of the process action that each available recipe segment performs.
Each recipe segment includes one or more data files for performing the corresponding process action on the set of equipment. The data files are preferably linked with at least one OLE object. Each recipe segment includes one or more recipe phases. Each process action includes one or more data files.
In the preferred embodiments in accordance with this aspect of the invention, the site information includes optimization information. The method includes using the optimization information to select at least one optimal production path from the set of production paths to create the set of master recipes from the optimal production paths.
In accordance with another aspect of the invention, a method is provided for automatically creating a set of master recipes from a general recipe using site information. Each master recipe comprises a plurality of recipe phases, the general recipe comprises a plurality of process actions, each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material by using recipe segments, the recipe segments comprise at least one recipe phase, each process action is performed by one recipe segment, each master recipe is for use with a specific set of equipment in a process cell, and each process action has one or more corresponding recipe segments that implement the process action on the set of equipment.
The general recipe is for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material. The general recipe is independent of equipment.
In accordance with this aspect of the invention, the method comprises a first step of creating a list of recipe segments from the general recipe and the site information, the list of recipe segments including each process action in the general recipe and a listing of all the corresponding recipe segments for that process action which can perform that process action in the process cell, and a second step of creating the set of master recipes from the list of recipe segments, the general recipe, and the site information.
In the preferred embodiments in accordance with this aspect of the invention, the method requires little or no human interaction or intervention. Each master recipe is for use with a single process cell. Each master recipe includes one or more a data files. The data file preferably is linked with at least one OLE object. The master recipe is preferably depicted by a procedure flow chart.
In the preferred embodiments, the process cell includes a batch control system interfacing the set of equipment. The batch control system is for controlling the operation of the set of equipment and each master recipe is for use with the batch control system to control the set of equipment in the process cell. Each master recipe may include at least one unit operation. Each master recipe may further include at least one unit procedure.
Further in accordance with the preferred embodiments of this aspect of the invention, the recipe segments are organized into at least one segment path in the master recipe. The at least one segment path is interconnected in a production path to form the master recipe. The process actions are organized into at least one process branch in the general recipe. The process branches are interconnected in a dependency path to form the general recipe. Each process branch has one or more corresponding segment paths that can perform the process branch on the set of equipment. The second step of the method includes the steps of dividing the general recipe into the dependency path and a collection of process branches, and using the list of recipe segments to analyze each process branch in the collection of process branches to create a segment path series for the process branch. The segment path series includes all the segment paths corresponding to the process branch. The analysis results in a collection of segment path series corresponding to the collection of process branches. The method also includes the step of using the collection of segment path series, the dependency path, and the site information to create a set of production paths, and a step of using the set of production paths, the collection of segment path series, and the site information to create a set of master recipes.
The at least one process branch typically is or includes two or more process branches. Each process branch has a branch end. The dependency path includes at least one material join the material joins connect at least two branch ends. The segment paths are for processing at least one material separately without a material join from another segment path. The process branches describe how to process the at least one material separately without a material join from another process branch. The at least one material is an input material, a product, or an intermediate material.
In the preferred embodiments in accordance with this aspect of the invention, the general recipe includes one or more data files. The data files are linked with at least one OLE object. The general recipe preferably is depicted by one or more process dependency charts. The general recipe preferably is depicted by one or more a process sequence tables. Alternatively, but preferably, the general recipe is depicted by one or more sequence function charts. Each general recipe may include at least one process operation. Each general recipe may also include at least one process stage.
In the preferred embodiments, the site information includes one or more data files. The recipe segment information includes a listing of all the recipe segments available to perform the process actions in the process cell and a summary of the process action that each available recipe segment performs.
Each recipe segment includes one or more data files for performing the corresponding process action on the set of equipment. The data files are preferably linked with at least one OLE object. Each recipe segment includes one or more recipe phases. Each process action includes one or more a data files.
In the preferred embodiments in accordance with this aspect of the invention, the site information includes optimization information. The method includes using the optimization information to select at least one optimal production path from the set of production paths to create the set of master recipes from the optimal production paths.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments and methods of the invention and, together with the general description given above and the detailed description of the preferred embodiments and methods given below, serve to explain the principles of the invention.
FIG. 1 depicts an illustrative company with multiple manufacturing sites;
FIG. 2 depicts an example process cell layout;
FIG. 3 depicts the elements of a unit;
FIG. 4 is a simple block diagram of the first preferred embodiment of the invention;
FIG. 5 illustrates the relationship between a general recipe, master recipe, and equipment;
FIG. 6 shows the subdivision of elements in a master recipe;
FIG. 7 illustrates the relationship between the procedural elements of a general recipe and a master recipe;
FIG. 8 is a simplified comparison of the procedural steps of a general recipe and a master recipe;
FIG. 9 is an example recipe segment for a process action;
FIG. 10 is another simplified comparison of the procedural steps of a general recipe and a master recipe;
FIG. 11 is a block diagram for a second preferred embodiment of the invention;
FIG. 12 is the process cell configuration for the first example;
FIG. 13 is a depiction of a general recipe for the first example;
FIG. 14 is another depiction of the general recipe for the first example;
FIG. 15 is shows material flow information for the process cell of the first example;
FIG. 16 shows recipe segment information and material flow information for the process cell of the first example;
FIG. 17 shows unit start and unit end recipe segments for the process cell of the first example;
FIG. 18 shows equipment information for the process cell of the first example;
FIG. 19 is another block diagram for the preferred embodiments of the invention;
FIG. 20 is another block diagram for the preferred embodiments of the invention;
FIG. 21 is a block diagram in accordance with the preferred embodiments for expanding the general recipe;
FIG. 22 is a block diagram in accordance with the preferred embodiments for creating the preliminary list of recipe segments;
FIG. 23 is a block diagram in accordance with the preferred embodiments for creating the list of recipe segments;
FIG. 24 is a block diagram in accordance with the preferred embodiments for creating the collection of segment path series;
FIG. 25 is a block diagram in accordance with the preferred embodiments for creating the dependency path;
FIG. 26 is a block diagram in accordance with the preferred embodiments for creating the segment paths;
FIG. 27 is a block diagram in accordance with the preferred embodiments for creating the production paths;
FIG. 28 is a block diagram in accordance with the preferred embodiments for determining the optimal production paths;
FIG. 29 is a block diagram in accordance with the preferred embodiments for determining the production path with the minimum number of material movements;
FIG. 30 is a block diagram in accordance with the preferred embodiments for determining the production path with the closest match of process action and recipe segment parameter ranges;
FIG. 31 is a block diagram in accordance with the preferred embodiments for determining the production path with the minimum or maximum user defined weighting factor;
FIG. 32 is a block diagram in accordance with the preferred embodiments for constructing the master recipes;
FIG. 33 is a block diagram in accordance with the preferred embodiments for creating the recipe procedure structure;
FIG. 34 is a block diagram in accordance with the preferred embodiments for inserting the transfer recipe segments;
FIG. 35 shows the general recipe of the first example including the underlying process actions and process operations;
FIG. 36 shows process stages 2 and 4 of the general recipe of the first example including the material joins and process branches;
FIG. 37 shows the exploded general recipe for the general recipe of the first example;
FIG. 38 shows the dependency path for the general recipe of the first example;
FIG. 39 is a tabular representation for the dependency path of FIG. 38;
FIG. 40 is a detailed depiction of the general recipe of the first example including the identification of the material joins and the process branches;
FIG. 41 shows the preliminary list of recipe segments for process branch 3 of the of the general recipe of the first example;
FIG. 42 shows the list of recipe segments for process branch 3 of the of the general recipe of the first example;
FIG. 43 shows the nomenclature and identification schemes used for the segment paths for the first example;
FIG. 44 shows the segment paths for process branch 3 of the general recipe of the first example;
FIG. 45 shows all the possible segment paths corresponding to the process branches of the general recipe of the first example arranged in the structure of the dependency path;
FIG. 46 shows one of the possible production paths corresponding to the dependency path of the general recipe of the first example;
FIG. 47 shows all of the possible production paths corresponding to the dependency path of the general recipe of the first example;
FIG. 48 illustrates the opening of parallel unit procedures during the initial phases of master recipe construction;
FIG. 49 illustrates a unit procedure including unit start and end recipe segments;
FIG. 50 is an example of a unit start recipe segment;
FIG. 51 is an example of a recipe segment, its corresponding process action, and the unit in process cell associated with the process action;
FIG. 52 depicts the creation of new unit operations during master recipe construction;
FIG. 53 is an example of a process operation of a general recipe;
FIG. 54 provides the recipe segments for the process actions of the process operation of FIG. 53;
FIG. 55 is a unit operation corresponding to the process operation of FIG. 53;
FIG. 56 shows a master recipe under construction with a unit procedure being created prior to the insertion of the unit operation of FIG. 55;
FIG. 57 shows the master recipe of FIG. 56 after the insertion of the unit operation of FIG. 55;
FIG. 58 is an example of a unit transfer between two units with no parallel unit operations;
FIG. 59 is an example of a unit transfer between two units with parallel unit operations in both units;
FIG. 60 is an example of a unit transfer between two units with parallel unit operations in the receiving unit;
FIG. 61 is an example of a unit transfer between two units with parallel unit operations in the transfer from unit;
FIG. 62 is an example of a material join involving three units with parallel unit operations in the two transfer from units;
FIG. 63 is an example of a material join involving three units with parallel unit operations in all three units;
FIG. 64 is an example of a material join involving two units with parallel unit operations both units;
FIG. 65 shows a unit transfer with parallel operations in both unit and a dummy unit procedure inserted allowing deallocation of one of the units before the parallels complete;
FIG. 66 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for a summary of header information for the general recipe of the second example;
FIG. 67 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for header information for the general recipe of the second example;
FIG. 68 shows another view from the general recipe editor in accordance with the preferred embodiments of the invention for header information for the general recipe of the second example;
FIG. 69 shows still another view from the general recipe editor in accordance with the preferred embodiments of the invention for header information for the general recipe of the second example;
FIG. 70 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the process inputs for the general recipe of the second example;
FIG. 71 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the products for the general recipe of the second example;
FIG. 72 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the process dependency chart for the general recipe of the second example;
FIG. 73 shows the flow symbols for the flow diagram of the general recipe view of FIG. 72;
FIG. 74 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the process details of the Sulferize process stage for the general recipe of the second example;
FIG. 75 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for general information associated with an "Add" process action for the general recipe of the second example;
FIG. 76 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for process input information associated with an "Add" process action for the general recipe of the second example;
FIG. 77 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the process parameters associated with an "Add" process action for the general recipe of the second example;
FIG. 78 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for history information associated with an "Add" process action for the general recipe of the second example;
FIG. 79 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for process output information associated with a "Dump" process action for the general recipe of the second example;
FIG. 80 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the process details of the Esterify process stage for the general recipe of the second example;
FIG. 81 shows a view from the general recipe editor in accordance with the preferred embodiments of the invention for the process details of the Separate process stage for the general recipe of the second example;
FIG. 82 shows a view from the OPENBATCH professional recipe editor in accordance with the preferred embodiments of the invention for the Procedure Flow Chart for the master recipe of the second example;
FIG. 83 shows a view from the OPENBATCH professional recipe editor in accordance with the preferred embodiments of the invention for header information for the master recipe of the second example;
FIG. 84 shows a the Procedure Flow Chart for the unit operation Sulferize_OP:1 from the master recipe of the second example;
FIG. 85 shows a the detailed Procedure Flow Chart for the unit procedure Sulferize_UPC:1 from the master recipe of the second example;
FIG. 86 shows a the detailed Procedure Flow Chart for the unit procedure Esterify_UPC:1 from the master recipe of the second example;
FIG. 87 shows a the detailed Procedure Flow Chart for the unit procedure Separate_UPC:1 from the master recipe of the second example;
FIG. 88 is a table showing the relationship between the process actions of the general recipe of the second example and the recipe segments from the corresponding master recipe for the example;
FIG. 89 shows a view from the OPENBATCH professional recipe editor in accordance with the preferred embodiments of the invention for a recipe segment from the master recipe of the second example;
FIG. 90 shows a view for mapping recipe segment parameters to process action parameters in accordance with the preferred embodiments of the invention;
FIG. 91 shows a view for editing recipe phase parameters of the master recipe in accordance with the preferred embodiments of the invention;
FIG. 92 shows a view for reviewing reports associated with recipe phases of the master recipe in accordance with the preferred embodiments of the invention;
FIG. 93 shows a view for reviewing messages associated with recipe phases of the master recipe in accordance with the preferred embodiments of the invention;
FIG. 94 shows the process cell configuration for the second example;
FIG. 95 shows the unit configuration for unit Premix_A from the process cell of the second example;
FIG. 96 shows the unit configuration for unit Reactor.sub.-- 1 from the process cell of the second example;
FIG. 97 is a view for editing equipment information associated with units in the process cell in accordance with the preferred embodiments of the invention;
FIG. 98 is another view for editing equipment information associated with units in the process cell in accordance with the preferred embodiments of the invention;
FIG. 99 is still another view for editing equipment information associated with units in the process cell in accordance with the preferred embodiments of the invention; and
FIG. 100 is a representation of the Sulferize process stage from the general recipe of the second example using a sequence function chart.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND METHODS
Reference will now be made in detail to the presently preferred embodiments and methods of the invention as illustrated in the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not limited to the specific details, representative devices and methods, and illustrative examples shown and described in this section in connection with the preferred embodiment and method. The invention according to its various aspects is particularly pointed out and distinctly claimed in the attached claims read in view of this specification, and appropriate equivalents.
In accordance with one aspect of the invention, a method is provided for automatically creating a set of master recipes from a general recipe using site information.
In the presently preferred embodiment according to this aspect of the invention, the master recipe is for use in a process company 10 at a manufacturing site 12 to control the batch manufacture of at least one product, as will be described in more detail later. The company may have multiple sites as shown in FIG. 1. Each manufacturing site has at least one process cell 14, which manufactures the product or group of products. The process cell has a set of equipment 16 located in the cell, which is used to process materials and manufacture the products. The process cell 14 has a batch control system 18 that controls operation of the process cell. The batch control system preferably includes a batch server 20 that interfaces the process cell through the process connected devices 22. There may be one batch control system 18 for each process cell 14, or the batch control system may interface and control multiple process cells. The process connected devices 22 are preferably process controllers or equipment with the capability of directly communicating to the batch server 20. The process connected devices 22, or PCD's, are electrically or physically connected to the set of equipment 16. The process controllers include both the software programming and logic to interface with and control the operation of the set of equipment. Typical process controllers are made by various companies throughout the control industry. Examples of adequate process controllers were provided previously under the Background of the Invention section of this document. The batch control system 18 may be connected to the site computer system 24. The site computer system may be connected to a company 10, or global computer system 26, such as a global enterprise resource planning system, or ERP.
The batch server preferably interfaces the PCD's by industry standard interface software such as WINDOWS.RTM. Dynamic Data Exchange, or WINDOWS.RTM. DDE by Microsoft Corporation of Redmond, Wash., or OPC defined by the OPC Foundation, Boca Raton, Fla. This software provides the communications protocols for the communication link between the PCD's 22 and the batch control system 18 through the batch server 20. The process connected devices 22 are connected to the batch server by industry standard communication connections, such as Modbus by Schneider Electric of North Andover Mass., DeviceNet by Open Devicenet Vendors Association of Boca Raton Fla., Profibus by Siemens Corporation of Munich Germany, and Data Highway by Honeywell Corporation of Minneapolis Minn. The batch server 20 preferably has a process control application, or PCA, such as a batch control software application operating on it to allow operators to interface with the process cell 14. This allows the operators to monitor and control the set of equipment 16 in the process cell directly from the batch control system. The preferred PCA is Open Batch by Sequencia Corporation of Phoenix, Ariz. The batch server 20 is any configuration of computer that will operate the PCA and allow the operators to control the process cells to manufacture the products. The batch server 20 has the appropriate software loaded on the server required by the PCA. A typical configuration of a preferred server is an IBM type personal computer with a minimum of a 300 megahertz Pentium processor with 256K of cache RAM by Intel Corporation of Santa Clara, Calif. or equivalent with a minimum of 128 megabytes of RAM, a 2 gigabyte hard drive, a 20X CD ROM, a 10 megabit Ethernet Card, a 31/2 inch floppy drive, a 512K 800.times.600 resolution graphics card, an 800.times.600 resolution VGA 17 inch monitor, and a UPS with 1/2 hour rating. The server 20 preferably has the following minimum software loaded and operating on it: WINDOWS.RTM. NT 4.0, WINDOWS DDE, and SQL Server Version 7 by Microsoft Corporation of Redmond Wash. and OPENBATCH, Batch Service Manager, and Batch History Archiving by Sequencia Corporation of Phoenix, Ariz. The batch control system 18 preferably has operator terminals configured to allow the operator to interface the system. One server may support multiple terminals or clients. These terminals are typically personal computers with a configuration sufficient to allow the operators to access the batch control system 18 and perform their duties. An example configuration for an operator terminal is an IBM type personal computer with a minimum of a 166 megahertz Pentium processor with 256K of cache RAM by Intel Corporation of Santa Clara, Calif. or equivalent with a minimum of 64 megabytes of RAM, a 1 gigabyte hard drive, a 20X CD ROM, a 10 megabit Ethernet Card, a 31/2 inch floppy drive, a 512K 800.times.600 resolution graphics card, an 800.times.600 resolution VGA 17 inch monitor, and a UPS with 1/2 hour rating. The terminal preferably has the following minimum software loaded and operating on it: WINDOWS.RTM. NT 4.0, WINDOWS.RTM. DDE, and SQL Server Version 7 by Microsoft Corporation of Redmond Wash. and OPENBATCH, BATCH SERVICE MANAGER, and BATCH HISTORY ARCHIVING by Sequencia Corporation of Phoenix, Ariz. The batch control system 18 from any one process cell 14 is preferably connected to the site computer system 24 so that other personnel may access some or all of the data and features provided by the process control application.
In the preferred application, the set of equipment 16 in the process cell 14 is preferably process equipment for batch processing lots of bulk materials such as gases, liquids, or bulk solids such as powders or granules. This variety of equipment is commonly used throughout the chemical, pharmaceutical, and food industries, as previously described. The set of equipment 16 is typically arranged in the process cell 14 with a specific equipment layout 28 which includes the location of the equipment within the process cell as well as the allowable material flow paths 30 within the process cell and between the equipment. The material flow paths 30 generally include flow control devices 32, such as valves, pumps, flow regulators, flow meters, etc., to route and control the flow of materials throughout the process cell as shown in FIG. 2. The material flow paths 30 route input materials into the process cell and into the equipment, process intermediate materials between the equipment within the process cell, and final products out of the process cell.
The set of equipment 16 in the process cell 14 is broken down into units 34 that are for processing a batch of material, as shown in FIG. 3. These units are typically capable of holding the batch of material as it is being processed. They often consist of large reservoirs 35 that hold the material and the associated equipment module 36 that performs the processing of the batch of material. The equipment module 36 is a collection of control modules 38 that are associated with a specific unit 34. Each equipment module 36 can carry out a finite number of specific processing activities related to the unit 34 with which they are associated, for example, a weigh tank, a process heater, a scrubber, etc. The control modules 38 are the lowest level of grouping of equipment that can carry out basic control, such as a valve and the associated solenoid to open and close the valve. The control modules 38 are preferably connected to a process connected device 22 or are themselves a process connected device in communication with the batch control system 18. The batch control system 18 controls manufacture in the process cell 14 through its interface to the control modules 38 within the process cell. Although each control module typically can be operated independently of all of the other control modules in the process cell, the logical grouping of the control modules 38 into the hierarchy of equipment modules 36, units 34, and process cells 14 provides for a more organized picture of the process equipment. This structure often simplifies the task of controlling a process to manufacture a product.
Each piece of equipment in the process cell has a variety of characteristics associated with it. These characteristics include capabilities (such as capacities, maximum and minimum limits, material compatibilities, etc.), classifications (such as unit, control module, heater, chiller, scrubber, reactor, etc.), associations with other equipment (such as identification of material flow paths to other equipment, unit ID with which a control or equipment module is associated, etc.), etc. All this information is specific to a process cell 14 and a site and constitutes site information 40, as discussed in more detail later.
Further in accordance with the preferred embodiments of this aspect of the invention, a method is provided for automatically creating a set of master recipes 42 from a general recipe 44 using site information 40, as depicted in FIG. 4. The set of master recipes 42 created from the general recipe 44 are a group of discrete master recipes 46 which can manufacture the product to the process requirements of the general recipe in the process cell 14 or in a class of process cells with a common equipment configuration. The set of master recipes may consist of as few as one master recipe if only one master recipe exists which will meet the constraints of the general recipe and the site information.
When used with the preferred embodiments, the batch control system 18 controls the manufacture of products in the process cell 14 through the use of the master recipe 46. The master recipe 46 defines how to supervise and control the set of equipment 16 in the process cell 14. As described previously, the master recipe preferably is a quantity independent recipe for manufacturing a specific product or group of products from at least one input material. A master recipe 46 may produce one product or a group of products in a single batch, depending upon the recipe. As used herein, the term product refers to a specific product or a specific group of products manufactured to the master or control recipe in a single batch. The master recipe 46 preferably includes all the process and equipment specific information necessary to manufacture the product, except the master recipe preferably is normalized with respect to quantity. The master recipe 46 is generally used to create the control recipe. The control recipe is the batch specific recipe to manufacture the product, as previously described. Alternatively, the master recipe 46 may be the control recipe as described previously.
The master recipe 46 preferably is for the control of the manufacture of the product automatically, so that no human interaction is required between the batch control system 18 and the operator. Alternatively, the master recipe 46 can allow for partial or complete manual control of the manufacture of the product. In either case, the master recipe simplifies the operator's tasks by providing specific and detailed operating instructions in the order required for the recipe. The instructions could be either fully automatic control commands to control the equipment or devices (such as a valve or pump) or manual instructions to operators, or any combination of the two. For example, the control recipe issues an "Open" command to a valve or a "Start" command to a pump, and the automated devices go to the command state. Alternatively, the operator controls a material addition by specifying the amount of material to be added and actuating the addition of the material through the batch control system; however, the master recipe may perform multiple tasks, such as opening valves, actuating pumps, monitoring flow meters or load cells, turning off pumps, closing valves, etc., to accomplish the addition for the operator. Even a fully manual master recipe will most likely guide the operator through the steps of the recipe to simplify the operator's tasks. The operator may be allowed to perform tasks other than the standard task required by the recipe, but he might be provided the standard tasks in order before being allowed the option to over ride.
The master recipe 46 is preferably for the control of either one process cell 14 or multiple process cells of one process cell configuration. The master recipe 46 may be used with more than one process cell 14, provided each process cell the master recipe is used with has the same process cell configuration. For the process cell configuration to be the same, the process cell 14 must have an identical interface to the batch control system 18. In other words, each process cell 14 must look identical to the control system 18. In general, this means that the equipment in the process cell 14, as well as the layout of the equipment 28 and the material flow paths 30 between the equipment must be the same between the process cells.
The master recipe 46 preferably is one or more data files, which contain the procedure, required to manufacture the product. The master recipe 46 is preferably for use with the process control application residing on the batch control system 18. The master recipe 46 provides the necessary data required to operate the set of equipment 16 in the process cell through the process control application. The form and type of data file are preferably selected to operate with the process control application. For use with the preferred process control application, OPENBATCH by Sequencia Corporation, the master recipe data file type is preferably either a binary file or a relational database. The data file type is preferably selected by the user from one of the preferred data file types. Alternatively, the master recipe 46 may be one or more program routines or subroutines that operate on the batch control system 18. A combination of data files and subroutines may be used as well. The exact form of the master recipe 46 does not matter, provided it is capable of implementing the master recipe on the batch control system 18 to manufacture the product. Similar to the master recipe 46, the preferred embodiments of the general recipe 44 are one or more data files. Alternatively, the general recipe 44 may be one or more program routines or subroutines. Like the master recipe, the exact form of the general recipe 44 does not matter, provided it is capable of describing how to manufacture the product, as will be described in more detail later.
In the preferred embodiments, both the master recipes 46 and the general recipes 44 include the five major elements identified in ISA S88.01. These elements are the header, formula, equipment requirements, procedure, and other information. These major elements preferably contain the same information in them that is identified in ISA S88.01. The following is a summary description of the information provided in each of these major elements in accordance with ISA S88.01. The definition of process input, process output, and process parameter provided as well for the sake of clarity:
Header--The administrative information in the recipe, usually including the recipe and product identification, the version number, the originator, the issue date, approvals, status, and other administrative information.
Formula--The category of recipe information that includes process inputs, process outputs, and process parameters. The type of data provided in the formula is that which may be needed by different parts of the enterprise, without including processing details not required by the balance of the enterprise. For example, the formula usually includes a general bill of materials and a bill of materials segregated by procedural elements.
Equipment Requirements--The category of recipe information that includes equipment constraints which limit the choice of equipment which may be used to manufacture the product. For the general recipes these constraints are typically broad, such as allowable equipment materials of construction and required processing characteristics, such as categories of allowable mixer types. For the master recipes the equipment requirements often limits the equipment to specific units, such as reactor R-5, or they may limit the equipment to vary specific classes of units.
Procedure--The category of recipe information that defines the actual strategy for carrying out the process, preferably in a step by step manner. In the case of general recipes, the procedure is independent of equipment and describes the basic material related process for creating the product. In the case of master recipes, the procedure includes both the equipment and the material processing details required to manufacture the product in a specific process cell or configuration of process cells.
Other Information--The category of recipe information that includes batch processing information not included in the other four categories of information. Examples include regulatory compliance information, materials and process safety information, process flow diagrams, and packaging and labeling information.
Process Input--The identification and quantity of a raw material or other resource required to make a product.
Process Output--An identification and quantity of material or energy expected to result from one execution of a control recipe.
Process Parameter--Information that is needed to manufacture a material but does not fall into the classification of process input or process output.
In the preferred embodiments, the procedure section of both the general 44 and master recipes 46 may be divided into a hierarchy of elements, as shown in FIG. 5. The top level element in the master recipe 46 is procedure 48. Under the procedure are unit procedures 50. The unit procedures are subroutines or sub-procedures that identify a specific, major operation that is carried out on one unit 34. The ISA S88.01 definition for a unit procedure is "a strategy for carrying out a contiguous process within a unit. It consists of contiguous operations and the algorithm necessary for the initiation, organization, and control of those operations." The next level of subdivision in the master recipes 46 are the operations 52. Operations are typically the procedural elements necessary to accomplish one task, such as charge, react, mix, etc. As defined by ISA S88.01, the operations are "the procedural element defining an independent processing activity consisting of the algorithm necessary for the initiation, organization, and control of phases." Phases 54 are the lowest level of procedural control available to the batch control system 18. Phases correspond to a single, discrete action available to the process control system in the process cell 14 on the set of equipment 16. As defined in ISA S88.01, a phase is "the lowest level of procedural element in the procedural control model." Examples of the actions performed by recipe phases 54 are the opening of a valve, the actuation of a mixer, the actuation of a pump, the reading of a meter or gauge, etc. Recipe phases 54 are the only necessary procedural elements to perform the procedure 48 of a master recipe. They are the procedural elements corresponding directly to the discrete physical actions or process communications, such as the reading of a value, being performed on the materials in the process cell. The unit procedures 50 and operation 52 do not need to be present in a discrete and identifiable form to create the procedure 48 in the master recipe 46. All the procedural elements, when they are present in the master recipe, preferably are in the same general form of the master recipe 46. Specifically, they include a header, a formula, equipment requirements, a procedure, and other information. FIG. 6 depicts the nested nature of the hierarchy of elements in master recipe 46, each element including a header, a formula, equipment requirements, a procedure, and other information, much the same as the master recipe itself.
FIGS. 6 and 7 illustrate the division of possible procedural elements in a master recipe 46. The master recipe is subdivided into the unit procedures, unit operations, and recipe phases. As described previously, each of these elements is in the same basic format as the master recipe itself, that is, each element includes the same five categories of information as the master recipe--a header, a formula, equipment requirements, a procedure, and other information. The actual information contained in each of these categories of information is dependent upon which element the category pertains to. For example, the formula and equipment requirements for a recipe phase 54 are very specific. The formula may include material A as the process input and may specify valve 3b as the equipment requirements. The procedure may be actuated at 5 volts for 3 minutes. The same basic data structure used for the master recipe 46 is used for any of the modular subcomponents of the master recipe to provide a consistent form for all recipe components. This simplifies the process of analyzing data associated with recipes. The same basic data structure is also used for the general recipe 44a nd its subcomponents (for example, the process stages, process operation, and process actions).
The preferred hierarchy of procedural elements in the general recipe 44 is process 56, process stage 58, process operation 60, and process action 62. This hierarchy follows the guidelines of ISA S88.01. The process 56 of the general recipe is the equipment independent procedure for manufacturing the product. As described previously, in the preferred embodiments the general recipe 44 includes the same five major elements as the master recipe 46--the header, the formula, equipment requirements, the procedure, and other information. The specific section of the general recipe 44 containing the process is the procedure section of the general recipe. Process is simply another name for the equipment independent procedure for manufacturing the product. Although the elements of the general recipe 44 and those of the master recipe 46 are often directly related, there is no one to one relationship between the elements. For example, there may be more than one master recipe procedure 48 for performing the process 56 of the general recipe, process stages 58 do not necessarily correlate to unit procedures 50, process operations 60 do not necessarily correlate to operations 52 in the master recipe, and process actions 62 generally require more than one recipe phase 54 to perform the process action. The fuzzy relationship between the procedural elements of the general recipe and the master recipe is depicted in FIG. 7.
Further in accordance with this aspect of the invention, each master recipe includes a plurality of recipe segments arranged in a manufacturing sequence and the general recipe includes a plurality of process actions arranged in a process sequence. In the preferred embodiments, the procedure 48 of the master recipe 46 is composed of recipe segments 64 arranged in a manufacturing sequence 66 that defines the sequence of operations to manufacture the product. Each recipe segment 64 preferably is a group of recipe phases 54 that is organized to perform one specific process action 62 on one specific piece of equipment. Alternatively, each recipe segment 64 may be a group of recipe phases 54 that is organized to perform a specific process action on a set of equipment 16 with one specific equipment configuration, as will be described in more detail later. The process 56 of the general recipe is preferably composed of process actions 62 arranged in a process sequence 68 that defines the sequence of operations required to define the process of the general recipe. The relationship between these elements of the master recipe 46 and the general recipe 44 is depicted in FIG. 8. The division of the master recipe 46 into recipe segments 64 provides a logical grouping of the recipe phases 54. FIG. 9 depicts the recipe segment 64 for the process action 62 corresponding to a controlled material addition. The recipe phases 54 are represented by the blocks "agitate," "add fluoride," "add PHB," "sample," "add CHF," and "heat." The logic 70, or logical sequence of operation of the phases 54 and any corresponding states which must be true to begin and end a phase are depicted by the flow lines interconnecting the blocks which represent the phases 54 as well as the other logic symbols. The logical sequence 70 for a recipe segment 64 is essentially the equivalent of the manufacturing sequence 66 for the master recipe 46. The logical sequence 70 of a recipe segment 64 defines the order in which the recipe phases 54 must be executed to accomplish the process action 62 performed by the recipe segment. The flow chart depicted in FIG. 9 is in the form of a sequential function chart (SFC), also known as a procedure flow chart (PFC), and is drawn in accordance with the requirements of ISA S88.02. Appendix 1 provides further description of how to read an SFC or PFC. The elements of a general recipe 44 can be depicted in a flow diagram or chart form called a process dependency chart, or PDC, in accordance with ISA dS88.02. The elements of a PDC, and how to read them, are provided in Appendix 2. The figures for master recipes 46 and subcomponents of master recipes (such as unit procedures, unit operations, and recipe segments) provided herein which follow the SFC or PFC format of ISA S88.02 shall be interpreted in accordance with ISA S88.02 and Appendix 1. The figures for general recipes 44 and subcomponents of general recipes (such as process stages, process operations, and process actions) provided herein which follow the PDC format of Appendix 2 shall be interpreted in accordance with Appendix 2.
The grouping of recipe phases 54 within the master recipe 46 into recipe segments 64 (which perform the process actions of the general recipe in the process cell) provides a relationship between the elements of the process 56 in the general recipe and the elements of the procedure 48 of the master recipe. This allows the general recipe 44 to be mapped to the process cell 14, as will be described in more detail later. Thus, for every process action 62 in the general recipe, there should be at least one corresponding recipe segment 64 available to the batch control system 18 which performs that process action in the process cell 14. If this is not true, the general recipe typically cannot be converted to a master recipe and cannot be performed in that process cell.
The manufacturing sequence 66 corresponds to the order in which the recipe segments 64 and recipe phases 54 should be performed in the process cell 14 to manufacture the product. The manufacturing sequence is defined by both the product and process constraints and the equipment constraints. The process sequence 68 corresponds to the order in which the process actions 62 should be performed to manufacture the product independent of equipment constraints. The process sequence 68 may be viewed as a manufacturing sequence 66 in an ideal process cell in which the equipment does not impose any additional constraints above and beyond those required by the process 56. Generally, the process sequence 68 is the simplest manufacturing sequence possible to produce the product. The one to one or more relationship between the process actions 62 and the recipe segments 64 allows the process sequence 68 to be used as an initial guess at the manufacturing sequence 66 when converting a general recipe 44 to a set of master recipes 42, as will be described in more detail later.
FIG. 8 provides a simplified representation of the organization of the process actions 62 in a general recipe 44 and the organization of the recipe segments 64 in a master recipe 46 corresponding to the general recipe. Referring to FIG. 8, the process sequence 68 corresponds to the order in which the process actions are performed in the process 56. In FIG. 8 this is represented by the order of the process actions listed from the top to the bottom. The process actions 62 can be repeated, as is shown in FIG. 8. This is because each process action 62, for example heat, may need to be performed multiple times in a single process 56.
The master recipe 46 corresponding to the general recipe 44 in FIG. 8 has more recipe segments 64 than the number of process actions 62 listed in the general recipe in the figure. The recipe segments 64 of the master recipe 46 which correlate to a specific process action 62 in the general recipe 44 are shown by the dashed line between the process action and the recipe segment in FIG. 8. The identification scheme used for the recipe segments 64 in this figure is the unit number the recipe segment is performed in followed by the process action the recipe segment performs. For example, U1-1 is the recipe segment that performs process action 1 in unit U1. This identification scheme provides a simplified representation of the general and master recipes that aids in the visualization of the processes described herein. The detailed representation of the elements of the general and master recipes for use with the preferred embodiments of the invention are the PDC's and the PFC's respectively, as described previously.
The additional recipe segment U1/U2 for which no corresponding process action 62 exists represents a material transfer from unit U1 to unit U2 that is not included in the general recipe 44. As described previously, this recipe segment is not required by the equipment independent process of the general recipe, but the equipment constraints require the transfer to perform the master recipe in the process cell. This may be required, for example, if process action 7 is not available in U1 in the process cell, but is available in U2 as recipe segment U2-7. In this case, if the procedure begins in unit U1, the material must be transferred to unit U2 prior to the performing of process action 7 for the process of the general recipe to be performed in the process cell. As discussed previously, the process sequence 68 of the general recipe corresponds to the minimum manufacturing sequence required to manufacture the product (for example, if the constraints provided by the site information are not limiting). In the example provided in FIG. 8 the manufacturing sequence 66 requires one more step than the process sequence 68 due to the equipment constraints.
Further in accordance with this aspect of the invention, each master recipe is for manufacturing at least one product from at least one input material by performing the process actions on the at least one input material in the manufacturing sequence. In the preferred embodiments each master recipe is for manufacturing as least one product 72 from the at least one input material 74 by performing the process actions 62 on the input material 74 in the manufacturing sequence 66. Each master recipe 46 is for use with a specific set of equipment 16 in a process cell 14 and each process action 62 has one or more corresponding recipe segments 64 that implement the process action on the set of equipment. In the preferred embodiments, each master recipe 46 is for manufacturing a product or group of products 72 using the batch control system 18, as previously discussed. The master recipes 46 preferably provide the control algorithms to operate the process connected devices 22 in the process celli 14. If the master recipe 46 is a control recipe, it can be used to manufacture the product directly from the input materials 74 by operating the batch control system with the master recipe. FIG. 13 provides an example general recipe 44. If the master recipe 46 is a quantity independent master recipe, or a master recipe as otherwise defined in ISA S88.01, the master recipe can be used to manufacture the product 72 from the input materials 74 by inserting the quantity and batch or lot specific information into the master recipe to create the control recipe for the batch. In general, the specific quantities of input materials and products of a batch are determined by scaling the input materials and products of a recipe in proportion to one of the other materials, for example, one of the products in the recipe. The control recipe generated from the master recipe is then used to manufacture the lot of product requested. The latter scenario is often desirable when it can be integrated with an enterprise resource planning (ERP) system so that the lot and quantity specific information may be provided directly from the ERP system, such as SAP R/3 by SAP Corporation of Waldorf, Germany In this case, the quantity independent master recipe may be automatically converted to the control recipe using the information provided by the ERP system. This can be used to further reduce the level of operator interface, and the resulting costs and possible human errors that are often associated with the human interface.
The master recipes 46 are typically automatic, requiring little or no human interface to manufacture the product 72. This usually reduces manufacturing costs. Typically, an operator monitors the process on a control terminal communicating with the batch control system 18. He can monitor the process for any alarm conditions, provide any necessary operator input or decisions, and communicate to other functions and areas of the plant regarding manufacturing operations which are not fully automated.
Alternatively, the master recipe 46 could provide the manufacturing instructions to produce the product 72 to an operator 76 in a manual process cell 78, or in an automated process cell when manual manufacture of the product is required. The batch control system 18 for automatic or manual manufacture is depicted in FIG. 1. In this case, the process connected device is actually an instruction terminal 80 using a manual operator to perform the procedure on the set of equipment 16 in the process cell. This set up might be preferable if the process cell is not automated, or if the manufacturing operation is sensitive and requires a significant amount of human interface and decision making to assure the product is properly manufactured. This might be the case with pilot runs, or if the product is of a highly sensitive nature. The manufacturing procedure may be manual, automatic, or any combination of the two. This depends upon the needs of the company manufacturing the product, and will vary anywhere from one extreme to the other.
Further in accordance with this aspect of the invention, the general recipe is for describing how to manufacture the at least one product from the at least one input material by performing the process actions on the at least one input material in the process sequence. The general recipe is independent of equipment.
In the preferred embodiments, the general recipe 44 is for describing how to manufacture the at least one product 72 from the at least one input material 74 by performing the process actions 62 on the at least one input material in the process sequence 68. The process 56 of the general recipe 44 describes the order in which to perform the process actions 62, independent of equipment, as previously described. The general recipe 44 is analogous to the recipe one might use in the kitchen to make a cake, where the recipe does not specify what type of oven to use, or what type of mixer. It defines the minimum process necessary to manufacture the product without equipment constraints. The process actions 62 are the actual steps of the process required to perform the various material transformations that create the product from the input materials. For example, mix, heat, dry, etc. It should be noted that the at least one product 72 and the at least one input material 74 do not need to be matter, both the at least one product and the at least one input material could be in the form of energy, matter, or any combination thereof. For example, a processing plant may use waste heat from a reaction to heat water to steam, use the steam to drive a turbine mechanically coupled to a generator, and produce electrical power to use within the plant or to sell. In this case the at least one product 72 includes electrical energy.
In the preferred embodiments, the site information 40 is includes material flow information 82, recipe segment information 84, and equipment information 86. The master recipe 46 includes equipment specific and process cell specific information, as well as the process and product specific information of the general recipe 44. This information is contained in the site information 40 as shown in FIG. 4. As described previously, the master recipe 46 includes all the detailed information necessary to manufacture the product 72. The key differences between the master recipe 46 and the general recipe 44 may be better understood by the simplified example provided in FIG. 10. FIG. 10 provides a verbal description of the steps associated with the process 56 of a general recipe 44 to manufacture a product C from input materials A and B. FIG. 10 also provides a verbal description of the steps associated with the procedure 48 of a corresponding master recipe 46 which might be used manufacture the product C from input materials A and B in a specific process cell. In FIG. 10, each step in the general recipe is adjacent to the step in the master recipe that corresponds to the first step of the master recipe required to perform the adjacent general recipe step. For example, step 3 of the general recipe in FIG. 10, "Mix for 30 minutes at 1/2 turn over of material per minute" is performed by steps 15 through 22 of the master recipe. Steps 1-4 and 29-32 of the master recipe do not correspond to any of the steps of the general recipe. These steps are startup and shutdown steps required by the equipment in the process cell. In this verbal example of a general and master recipe, the steps in the general recipe are equivalent to process actions 62 and the steps in the master recipe are equivalent to recipe phases 54.
The general recipe 44 provides the product and process information and the master recipe 46 provides the product, process, equipment, and equipment configuration information. The general recipe 44 answers the questions of:
1. What consumable or input materials are required to manufacture the products, both type and quantity (normalized to product quantity)?
2. What are the products or by-products created by the recipe, both type and quantity (normalized to product quantity)?
3. What is the process to be performed to manufacture the product from the input materials (procedural steps and execution order)?
4. What additional material or process constraints (including equipment requirements such as materials of construction) are necessary to manufacture |
