Proficy* Batch Execution

APPLICATION GUIDE

Version 5.5
August 2009
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 Table of Contents
Why You Should Read This Guide ................................................................................ 1

Reference Documents ................................................................................................ 1

What's Inside .............................................................................................................. 2

Icon Index ...................................................................................................................... 3

Introduction to Batch Execution ......................................................................................... 4

Batch Execution Client-Server Architecture .................................................................. 5

Batch Execution System Components ....................................................................... 6

Batch Execution Server Nodes ............................................................................... 6

Batch Execution Client Nodes ................................................................................ 6

Batch Execution Development Node ...................................................................... 6

Integration with iFIX ...................................................................................................... 8

iFIX Supervisory Control and Data Acquisition (SCADA) ....................................... 8

iFIX Human-Machine Interface (HMI) ..................................................................... 8

Terminal Server Support for iFIX and Batch Execution ................................................ 8

Proficy Batch Execution WorkSpace ............................................................................. 9

VBIS............................................................................................................................. 10

ActiveX Controls ..................................................................................................... 11

ActiveX Control Modes ........................................................................................ 12

v
 Manufacturing Standards Compliance ......................................................................... 12

ISA S88.01 Standard ................................................................................................ 12

IEC 1131-3 Standard................................................................................................ 12

Designed for 21 CFR Part 11 ....................................................................................... 13

OPC Specification.................................................................................................... 13

Using the Batch Execution Demo Project .................................................................... 14

Batch Execution and the ISA S88.01 Models................................................................... 14

The Physical Model...................................................................................................... 16

Enterprise, Site, and Area Levels ............................................................................. 17

Process Cell.............................................................................................................. 18

Configuring Valid Execution Paths ...................................................................... 18

Unit .......................................................................................................................... 19

Equipment Modules and Control Modules .............................................................. 20

Procedural Control Model ............................................................................................ 23

Control Activity Model ................................................................................................ 25

Recipe Management................................................................................................. 26

S88.01 Recipe Types ............................................................................................ 27

Recipe Contents .................................................................................................... 29

Production Planning and Scheduling ....................................................................... 31

Production Schedule ............................................................................................. 31

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 Equipment Availability ......................................................................................... 32

Raw Material Availability .................................................................................... 32

Process Management ............................................................................................... 33

Unit Supervision ...................................................................................................... 33

Process Control ........................................................................................................ 34

Production Information Management ...................................................................... 34

Process Model .............................................................................................................. 35

Linking a Control Recipe to the Equipment ............................................................ 36

Exploring the Sample Application .................................................................................... 37

Designing the Toothpaste Control Strategy ................................................................. 38

Outlining the General Procedure.............................................................................. 38

Identifying the Process Flow ................................................................................... 39

Partitioning Plant Equipment ................................................................................... 39

Equipment Requirements ......................................................................................... 41

Other Samples .............................................................................................................. 41

Developing a Batch Execution Project ............................................................................. 42

Development Overview................................................................................................ 43

Reporting and Analyzing Production Data................................................................... 43

Active Journaling ..................................................................................................... 44

Archiving Process Values ........................................................................................ 45

vii
 Proficy Plant Applications Batch Analysis Reports ................................................. 46

Developing a Batch Execution WorkSpace Project ..................................................... 47

Embedding OLE Documents ................................................................................... 48

Using the Proficy iFIX WorkSpace ......................................................................... 49

Programming the Process Controller ........................................................................... 50

Understanding the PLI ............................................................................................. 51

Understanding the Phase Logic................................................................................ 52

Programming Requests ......................................................................................... 52

Configuring the Area Model ........................................................................................ 52

Area.......................................................................................................................... 53

Process Cell.............................................................................................................. 53

Unit Classes ............................................................................................................. 54

Unit Instances .......................................................................................................... 55

Standard Equipment Phases ..................................................................................... 55

Batch Direct Equipment Phases ............................................................................... 55

Developing Recipes...................................................................................................... 56

Using Active Binding .............................................................................................. 56

Requirement: ........................................................................................................ 56

Solution: ............................................................................................................... 56

Using Recipe Parameters ......................................................................................... 57

viii
 Requirement: ........................................................................................................ 57

Solution: ............................................................................................................... 57

Using Class-Based Recipes...................................................................................... 57

Requirement: ........................................................................................................ 57

Solution: ............................................................................................................... 57

Parallel Processing ................................................................................................... 59

Requirement: ........................................................................................................ 59

Solution: ............................................................................................................... 59

Storing Recipes in the Relational Database.................................................................. 59

Using the Batch Execution Soft Phase Server .............................................................. 60

Developing iFIX Pictures ............................................................................................. 61

Batch Execution Operations ............................................................................................. 61

Operations Overview.................................................................................................... 62

Understanding Batch Execution ................................................................................... 64

Understanding States ............................................................................................... 65

Controlling and Monitoring Batches ............................................................................ 66

Using the ActiveX Controls ..................................................................................... 67

Developing VBIS Applications ............................................................................... 69

Using the Campaign Manager.................................................................................. 69

Mastering Batch Execution............................................................................................... 70

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 Using Proficy Plant Applications Batch Analysis Reports........................................... 70

Understanding Active Binding ..................................................................................... 71

Configuring Active Binding in the Area Model....................................................... 72

Active Binding Configuration Based on Priority or Availability ......................... 72

Configuring Active Binding in Recipes ................................................................... 73

Example: Active Binding Area Model Configuration ............................................. 74

Equipment Pathing................................................................................................ 74

Unit Capacities and Statuses ................................................................................. 75

Example: Active Binding Recipe Configuration ..................................................... 76

Jacobson Links ..................................................................................................... 77

Forced Bindings .................................................................................................... 77

Equipment Requirements ...................................................................................... 78

Example: Active Binding at Run Time .................................................................... 79

Implementing a Class-Based Design ............................................................................ 80

Example: Class-Based Design ................................................................................. 80

Understanding Phase Synchronization ......................................................................... 81

Example: Phase Synchronization ............................................................................. 82

Area Model Configuration .................................................................................... 83

Recipe Configuration ............................................................................................ 84

Phase Logic Configuration ................................................................................... 85

x
 Extending Batch Execution with VBIS ........................................................................ 87

Integrating Batch Execution with ERP Systems ...................................................... 88

Using VBIS as an Integration Tool .......................................................................... 89

Using Electronic Signatures ......................................................................................... 90

Recipe Editor, Equipment Editor, and Batch Configuration .................................... 92

ActiveX Controls ..................................................................................................... 94

Audit Reporter ......................................................................................................... 95

Understanding Audit Versioning.................................................................................. 96

Viewing the Audit Trail ........................................................................................... 97

Appendix: Batch Execution Terminology ........................................................................ 99

Index ............................................................................................................................... 113

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Why You Should Read This Guide
This guide provides an overview of GE Fanuc's Batch Execution software by
introducing the major concepts and functionality in Batch Execution. It is intended
for users who are interested in understanding the application of Batch Execution,
engineers who are responsible for designing and configuring a Batch Execution
system, and users who need a general overview of the ISA S88.01 standard.

Reference Documents
Refer to the following Batch Execution manuals for detailed information on
configuring and using Batch Execution. These manuals are available in electronic
form. You can access these books by selecting Electronic Books from the Batch
Execution program group or from any Help menu.

• System Configuration Manual

• Phase Programming Manual
• PLI Development Manual
• Equipment Configuration Manual
• Recipe Development Manual
• WorkInstruction Manual
• Operations Manual
• Custom Applications manual

Also, refer to the standard, ISA-S88.01 Batch Control Part 1: Models and
Terminology, for further information on this standard as defined by the SP88
committee.

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Application Guide

What's Inside
• Introduction to Batch Execution – provides an overview of Batch
Execution.
• Batch Execution and the ISA S88.01 Models – describes the models as
defined by the SP88 committee and how Batch Execution adheres to
these models.
• Exploring the Sample Application – describes the sample toothpaste
demo that is shipped with Batch Execution.
• Developing a Batch Execution Project – provides an overview of the
development tasks required to develop a Batch Execution system.
• Batch Execution Operations – provides an overview of the operations
tasks used to execute batches in the Batch Execution Client.
• Reporting and Analyzing Production Data – describes the reporting
options provided by Batch Execution, including Active Journaling.
• Mastering Batch Execution – describes some of the more advanced and
powerful features in Batch Execution, such as Active Binding.
• Appendix: Batch Execution Terminology – provides a list of Batch
Execution terms and their definitions.

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 Why You Should Read This Guide

Icon Index
The icons for the following applications can be found in the Proficy Batch Execution
Program group, accessed from the Desktop or the Start menu. The table that follows
describes where to find more information for each application.

Icon Application Documentation

Proficy Batch Execution WorkSpace Application Guide

System Configuration
Manual

Equipment Editor Equipment Configuration

Manual

Recipe Editor Recipe Development

Manual

Batch Execution Server Manager System Configuration

Manual

Batch Execution Archiver Manager System Configuration

Manual

Batch Execution Soft Phase Server System Configuration

and OPC Simulator Manual

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Application Guide

Icon Application Documentation

Batch Execution Client Operations Manual

Batch Execution Services System Configuration

Configuration Utility Manual

WorkInstruction Editor WorkInstruction Manual

WorkInstruction EIB Server WorkInstruction Manual

Manager

Audit Reporter Audit Reporter Help

Electronic Books Batch Execution Electronic

Books

Introduction to Batch Execution

Batch Execution is a powerful, easy to use recipe management and batch execution
software system. Batch Execution combines the power of DCOM/COM, ActiveX,
OPC, and relational databases with the ease of graphical configuration. Batch
Execution addresses the challenges facing batch manufacturers both today and in the
future. With Batch Execution you can:

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 Introduction to Batch Execution

• Develop your equipment configuration and recipes from a single

intuitive location, the Proficy Batch Execution WorkSpace.
• Use Active Binding™ to maximize equipment productivity.
• Integrate with HMI and SCADA packages, including GE Fanuc's
offerings.
• Use VBIS to integrate batch data and recipes into your Enterprise
Resource Planning (ERP) system.
• Use the ActiveX controls supplied with Batch Execution to create a
customized Client application.
• Use Active Journaling™ to capture data in real-time and store
electronic batch records in your relational database. Comply with
regulatory agencies by generating customized batch reports from this
data.
• Advance your batch automation system with the latest manufacturing
technology based on the OPC (OLE for Process Control) specification.

The following sections introduce some of the key Batch Execution features.

Batch Execution Client-Server Architecture

Batch Execution uses a client-server architecture. The major benefits of a client-
server architecture include:

Scalability – additional clients and servers can be added to your process, if

necessary.

Flexibility – open and vendor-neutral data lets you integrate Batch Execution
into your manufacturing enterprise systems.

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Application Guide

Batch Execution System Components

A typical Batch Execution system consists of the following components:

• Batch Execution Server

• One or more Batch Execution Clients
• Development node

In addition, if you incorporate an HMI or SCADA system, such as the Proficy family
of software, your batch solution can include:

• One or more iFIX Run-time Clients

• One or more iFIX SCADA Servers

Each Batch Execution system component is described in the following sections.

Batch Execution Server Nodes

The Batch Execution Server is the batch engine that coordinates the function of your
recipes, area model, and each Batch Execution Client during production. The Batch
Execution Server also generates batch event data and communicates with iFIX
SCADA Servers, the relational database, and OPC-aware process hardware.

Batch Execution Client Nodes

In general, Batch Execution supports one or more Batch Execution Clients. An

operator manages and controls batches using the Batch Execution ActiveX controls
or the Batch Execution Client application. When a Batch Execution Client is
implemented within iFIX using the Batch Execution ActiveX controls, operators can
monitor process values residing in the iFIX process database directly on the same
screen. Operators using the Batch Execution Client application can also run iFIX
separately.

Batch Execution Development Node

The Batch Execution Development node is used to develop recipes and the area

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 Introduction to Batch Execution

model. During the development phase of your implementation, you can model and
test your process using the Soft Phase Server.

The following figure illustrates a typical Batch Execution system architecture.

Typical Batch Execution System Architecture

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Application Guide

Integration with iFIX

Batch Execution works in conjunction with the iFIX® SCADA and HMI software,
as well as many third-party applications.

iFIX Supervisory Control and Data Acquisition (SCADA)

iFIX SCADA is the application component that provides monitoring, supervisory
control, alarming, and control functions. It guarantees the absolute integrity of data
and provides complete distributed networking capabilities.

iFIX Human-Machine Interface (HMI)

iFIX HMI is the "window into your process." It provides all the tools you need to
develop pictures that operators can use to monitor your process.

Terminal Server Support for iFIX and Batch Execution

Proficy Batch Execution supports the iFIX Terminal Server functionality. The
guidelines for using Batch Execution with an iFIX Terminal Server include:

• Use the Windows 2003 or Windows Server 2008 (Standard or Enterprise

Edition) operating system on the iFIX Terminal Server computer, as
outlined in the iFIX electronic book.
• Install the Batch Execution Server on a computer that is separate from the
iFIX Terminal Server computer and Terminal Server Client computers.
• Install the Batch Execution Client Components on the iFIX Terminal Server
computer. Do not install or use the Batch Execution Server or EIB Server
on the iFIX Terminal Server computer.
• Use only the Batch ActiveX Controls from the iFIX WorkSpace on the iFIX
Terminal Server.

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 Introduction to Batch Execution

Be aware that the following applications are NOT supported on the iFIX Terminal
Server computer:

• Batch Execution Server

• VBIS Server
• WorkInstruction Server
• WorkInstruction Client
• Proficy Batch Execution Client

For information on the supported terminal server configuration, refer to the Using an
iFIX Terminal Server section of the System Configuration manual. For information
on how to configure the iFIX Terminal Server and the Terminal Server Clients, refer
to the iFIX Using Terminal Server electronic book.

Proficy Batch Execution WorkSpace

The Proficy Batch Execution WorkSpace is an intuitive application that lets you
graphically develop and maintain Batch Execution projects from a single location. A
Batch Execution project is the entire set of items needed to deliver a batch solution.
The Proficy Batch Execution WorkSpace provides a Microsoft® Explorer style
browser, allowing point-and-click access to all components of your projects. The
following figure illustrates each component of a Batch Execution WorkSpace
project.

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Application Guide

Proficy Batch Execution WorkSpace Project Components

In the figure illustrated above, you can see that Batch Execution integrates all the
necessary components for batch solutions within its environment. A detailed
discussion of the Proficy Batch Execution WorkSpace and its components is
presented in the Developing a Batch Execution Project section.

VBIS
As illustrated in the following figure, VBIS is a collection of automation interfaces
that allows external programs to monitor and control Batch Execution. Within VBIS,
services are provided in a number of functional areas including recipes, the area
model, scheduling, and batch execution.

10
 Introduction to Batch Execution

VBIS Architecture

ActiveX Controls
Batch Execution supplies a set of ActiveX controls that you can use to extend the
power of Batch Execution. You can use these controls as an alternative to the Batch
Execution Client application. You can "drop" these controls into any ActiveX control
container, such as:

• Proficy iFIX WorkSpace

• Web browsers, such as Microsoft® Internet Explorer
• Microsoft® Visual Basic®

You can also integrate these controls into custom applications. Each control provides
programmability through OLE automation. This allows you to take advantage of the
ActiveX control's features through the Microsoft Visual Basic or Microsoft® Visual
C++™ programming languages.

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Application Guide

ActiveX Control Modes

The Batch Execution ActiveX controls run as clients of VBIS. There are two modes
of use for the ActiveX controls: Run and Design. Run mode is when the control is
being used at run time, such as when the control is run from a web page. During Run
mode, there must be a connection to VBIS, either locally or remotely, over a
network. Design mode is when a user has inserted the control into Visual Basic or
Visual C++ to design the control, or into the Proficy iFIX WorkSpace in
configuration mode. A connection to VBIS is not necessary during Design mode.

Refer to the Custom Applications e-book for more information on VBIS and the
ActiveX controls.

Manufacturing Standards Compliance

Batch Execution adheres to the following manufacturing standards:

• The models and terminology outlined in the ISA S88.01 Batch Control Part
1: Models and Terminology standard.
• Sequential Function Chart (SFC) symbols as defined in the International
Electrotechnical Commission (IEC) 1131-3 standard.

ISA S88.01 Standard

The ISA S88.01 standard defines a consistent set of terminology and models used to
define the control requirements for batch manufacturing plants. Batch Execution is
designed using these models and incorporates the terminology defined in this widely-
accepted standard. For more information, refer to the Batch Execution and the ISA
S88.01 Models section.

IEC 1131-3 Standard

The IEC 1131-3 international standard defines the syntax, semantics, and display for
a suite of PLC programming languages, including Sequential Function Charts
(SFCs).

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 Introduction to Batch Execution

In Batch Execution, recipes are developed and built using SFCs. SFC programming
offers a graphical method for defining the logic of a recipe. The three main
components of an SFC are steps, actions, and transitions. Steps are sections of logic,
such as an operation in a recipe that accomplishes a particular task. Actions are the
individual aspects of that task. Transitions are the mechanisms used to move from
one step to another.

Designed for 21 CFR Part 11

The Food and Drug Administration (FDA) established the 21 CFR Part 11 regulation
(often referred to as Part 11) to establish criteria under which electronic records and
signatures will be considered equivalent to paper records and handwritten signatures.

Batch Execution provides enabling technology that supports compliance with 21

CFR Part 11. This assumes that the end user's Best Practices, Corporate Policies, or
Standard Operating Procedures (SOPs) are in place to enforce security measures and
ensure the safeguard of electronic records and signature information.

WorkInstruction is designed for 21 CFR Part 11. You can use WorkInstruction for
capturing electronic records in lieu of paper records during the execution of a batch.

OPC Specification
Based on Microsoft's OLE (Object Linking and Embedding) technology, OPC (OLE
for Process Control) provides greater interoperability between control applications,
field systems and devices, and front office/back office applications. OPC servers,
such as DCSs, PLCs, smart field devices, and analyzers provide real-time
information and can communicate directly with Batch Execution.

The Proficy Batch Execution Server is an OPC 2.0 DA enabled client, which lets
Batch Execution retrieve data from any OPC 1.0 or 2.0 compliant data server, such
as the iFIX OPC servers or the CIMPLICITY® HMI OPC server.

Be aware that Proficy iFIX currently includes an OPC 1.0 and OPC 2.0 server:

• OPCEDADLL.dll (Intellution.OPCEDA) – an OPC 1.0 (in process) Data

Server

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Application Guide

• OPC20iFIX.exe (Intellution.OPCiFIX) – an OPC 2.0 (out of process) Data

Server
IMPORTANT: Proficy Batch Execution only supports OPC servers running on the
SAME computer. Remote OPC servers are not supported.

You can find more information about OPC on GE Fanuc's web site at:

www.gefanuc.com/support

Using the Batch Execution Demo Project

Batch Execution supplies a fully functioning sample project based on a virtual plant
that makes toothpaste. You can use the demo as a reference when developing your
own Batch Execution application. Use the demo project to explore Batch Execution
from the development to the production stages of a batch manufacturing
environment.

For more information on the application of the demo project, refer to the Exploring
the Sample Application section.

Batch Execution and the ISA S88.01

Models
The ISA S88.01 standard defines a consistent set of terminology and models used to
define the control requirements for batch manufacturing plants. Batch Execution is
designed using these models and incorporates the terminology defined in this
standard. This sections that follow discuss the standard's models and terminology
and how Batch Execution conforms to these models.

NOTE: The information in this Application Guide is not intended to replace the ISA
S88.01 standard and does not represent a complete discussion of the information
provided in the standard.

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 Batch Execution and the ISA S88.01 Models

For information on obtaining a copy of the standard, access ISA's web site at:

http://www.isa.org

S88.01 Objectives

The S88.01 standards committee worked to develop a standard that provides

manufacturers with the tools they need to analyze their existing process and to
quickly add new products. The objectives of the S88.01 standard are to:

• Provide a common, consistent model for the design and operation of batch
manufacturing plants and batch control systems.
• Improve control and efficiency in batch manufacturing processes.

Models

In order to understand this model, the following significant models are discussed in
the sections that follow:

Physical Model – defines the hierarchy of the equipment used in the batch
process.

Control Activity Model – defines the relationships between the various control
activities required to perform batch processing.

Procedural Control Model – defines the control that enables equipment to

perform a process task.

Process Model – defines the results of performing procedural control on the

equipment in the process.

These models are designed to help you define the available equipment, recipes, and
the steps involved in manufacturing a product.

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Application Guide

The Physical Model

The equipment hierarchy in Batch Execution is based on the ISA S88.01 Physical
Model. The Physical Model, illustrated in the figure that follows, defines a hierarchy
consisting of several levels that identifies the equipment within a business enterprise.
For example, equipment modules are grouped together at a lower level to create a
unit in the next higher level.

The objective of this model is to define equipment that:

• You can group together to perform a specific function.

• Works as independently of each other as possible.

Performing this task requires you to have a clear understanding of the purpose of
each piece of equipment in your plant.

The S88.01 Batch Control Standard presents the following guidelines to define
equipment:

• Define each piece of equipment to perform a distinct and consistent task,

regardless of the product being manufactured.
• Define each piece of equipment to work independently.
• Establish a consistent set of rules to prevent confusion.

Each level in the Physical Model and its application to Batch Execution is described
in the following sections.

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 Batch Execution and the ISA S88.01 Models

The S88.01 Physical Model

Enterprise, Site, and Area Levels

The Enterprise, Site, and Area levels are determined by organizational or business
considerations. In Batch Execution, an area represents the highest level in the
equipment hierarchy. It contains one or more process cells. The equipment defined
within an area is called the area model.

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Application Guide

Process Cell
A process cell consists of all the production and supporting equipment necessary to
make a batch. In Batch Execution, you define a process cell class to set properties
that are inherited by all process cell instances. Process cell instances contain the
equipment-specific settings for the process cell.

The ISA S88.01 Batch Control Standard defines three types of process cell
structures:

Single path – A single path structure is a group of units through which a batch
passes sequentially.

Multiple path – A multiple path structure consists of several single path

structures in parallel, with no product transfer between them.

Network path – In a network structure, the paths may be either fixed or

variable. If the path is variable, the sequence is determined at the
beginning of the batch or during batch production. If the paths are fixed,
the same units are used in the same sequence.

Configuring Valid Execution Paths

As described above, a network path structure allows a batch to follow multiple

execution paths through a process cell. To ensure that batches execute on a valid
path, Batch Execution lets you configure the equipment paths that a batch can
follow. When equipment is allocated to a batch, Batch Execution checks that the
selected equipment is part of a valid execution path.

The example, shown in the following figure, illustrates the units contained in the
process cell for the demo application. This process cell is a multi-product, network
path structure. Making a batch of toothpaste, regardless of the flavor, can have
multiple paths. Raw material ingredients are first transferred into two mixers, where
they are agitated. Next, the ingredients from the mixers are transferred into the
Reactor unit, where they are combined to produce the final product.

The following figure highlights one of several paths the batch can take. In this
example, ingredients are transferred into MIX2 and MIX3, where they are agitated.

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 Batch Execution and the ISA S88.01 Models

After agitation, the mixtures are transferred into REACTFLAVOR.

Multi-Product, Network Path Process Cell

Unit
A unit is a major piece of equipment in a process cell that performs a specific task. It
consists of all the equipment and control modules that are needed to perform this
task. In Batch Execution, you define a unit class to define properties that are
inherited by all unit instances. Unit instances contain the equipment-specific settings
for the unit.

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Application Guide

When defining the units in your facility, use the following guidelines:

• A unit should perform one or more major processing tasks.

• Units should function independently of each other.
• The unit should be used on only one batch at a time.

The following figure illustrates the unit for mixer, MIX1, of the demo application.
MIX1 is one of three units in the MIXER unit class in the demo application. Note
that the unit consists of several smaller pieces of equipment that are controlled as a
single piece of equipment. The valve (XV101) in this example is included in the
mixer unit definition. If its function was more dependent on the storage tank, it
would be included in the RAW unit definition.

Sample Unit Configuration

Equipment Modules and Control Modules

Equipment modules and control modules are combined together to form a unit. In
Batch Execution, you define an equipment phase class for each type of phase
required in your process. You then create an instance of each equipment phase class

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 Batch Execution and the ISA S88.01 Models

for the unit's equipment module or control module on which the equipment phase
executes. An equipment phase is a phase that is part of the equipment control.

Equipment Module – consists of equipment and control modules that together

perform a minor processing task. In Batch Execution, you define an
equipment phase class (standard or Batch Direct) for each phase required
in your process. Each instance of the equipment phase class represents an
equipment module.

Control Module – consists of sensors and other control modules that together
perform a specific task. Control modules perform regulatory or state
control over their constituent parts. In Batch Execution, you can define
control modules as a common resource. You can assign the common
resource as needed equipment to a unit or an equipment phase.

The following figure shows the equipment phase classes that are defined to execute
the equipment modules on the MIXER unit class. These definitions apply to all
instances of the MIXER unit class, as the figure illustrates.

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Application Guide

Equipment Phase Classes for the MIXER Unit Class

The following figure illustrates the equipment phases for the MIX1 unit instance of
the demo sample project.

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 Batch Execution and the ISA S88.01 Models

Equipment Phases for the MIX1 Unit

Procedural Control Model

The Procedural Control model defines the hierarchy of required actions that must be
performed to complete a batch. The design of this model enables the construction of
generic instructions that recipes can use multiple times to make many different
products.

Batch Execution lets you create a standard set of reusable logic that you can
incorporate into the recipes of multiple products. Batch Execution lets you develop
and manage phases, operations, unit procedures, and procedures. The following
figure illustrates the Procedural model hierarchy.

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Application Guide

The Procedural Model Hierarchy

The following figure illustrates the procedure, unit procedure, operation, and phase
hierarchy of the sample toothpaste procedure, Make_Toothpaste.

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 Batch Execution and the ISA S88.01 Models

Procedural Control Hierarchy for the Sample Toothpaste Procedure

Control Activity Model

The Control Activity model defines the types of controls that must be available in
order to achieve a successfully managed batch production facility.

Batch Execution provides you with the tools that allow you to control your batch
process, including tools to create recipes, schedule batches, store batch data, and
manage the process. The figure in the Recipe Management section illustrates the
areas of this model that are provided by Batch Execution.

The following sections describe the functionality defined by the Control Activity
model, and the methods that Batch Execution incorporates to provide this
functionality.

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Application Guide

Recipe Management
Recipe Management is the practice of creating, storing, and maintaining general, site,
and master recipes.

Recipes, consisting of a procedure, header data, equipment requirements, and a set of

parameters, are defined in Batch Execution using the Recipe Editor. Only recipes
that are specified as "released" are made available to operators for production.

Batch Execution lets you manage recipes as either file-based or SQL-based formats.
Batch Execution stores file-based recipes on the local hard disk or on a network
drive. SQL-based recipes are stored in your relational database, where they can be
integrated into your Enterprise Resource Planning (ERP) system. When setting up a
Proficy Batch Execution WorkSpace project, you select the storage type (file or
SQL) for the project's recipes.

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 Batch Execution and the ISA S88.01 Models

Control Activity Model and Batch Execution

S88.01 Recipe Types

The S88.01 standard defines four types of recipes that a batch process can use. The
Batch Execution and Recipe Types figure illustrates these recipe types.

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Application Guide

General Recipe – defines the recipe as site and equipment independent. The
general recipe provides a very high-level view of requirements for
producing a product that can be used at many different sites. It includes
general information on required equipment, raw materials, and the
procedure without regard to production specifics. This version of a recipe
is usually created by a corporate chemist.

Site Recipe – derived from the general recipe by a process engineer, it includes
information that is site specific. The site recipe translates the general
recipe into a more specific version that allows for the types of equipment
and raw materials that are available at the site. This version of the recipe
is designed to be used in many different process cells.

Master Recipe – derived from the site recipe, it includes process cell-specific
information and accounts for actual equipment capabilities. Created by
the control engineer, it is designed to be used on many different lines
within the process cell.

The Batch Execution Recipe Editor provides you with the tools to create
master recipes for your products. A master recipe typically includes a
procedure, a header, a set of parameters, and equipment requirements.

Control Recipe – created from the master recipe when a batch is scheduled for
production, it defines the manufacture of a single batch of a specific
product.

This control recipe is the most specific version of the recipe. It is created
when a batch is scheduled and includes information that is specific to the
equipment on which the batch is produced and the raw material that is
used.

When batches are scheduled for production, Batch Execution automatically creates a
control version of the master recipe. The control recipe contains specific information
for the batch. This includes the recipe parameter values and the equipment on which
the batch executes.

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 Batch Execution and the ISA S88.01 Models

Batch Execution and Recipe Types

Recipe Contents

Each recipe, regardless of its type, consists of four parts that, when combined
together, provide all the information needed to produce product. The following
figure illustrates the recipe contents.

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Application Guide

Batch Execution Recipe Contents

The Batch Execution Recipe Editor builds master recipes that are used in batch
production. Master recipes that are configured as released to production can be
scheduled for production by operators.

In Batch Execution, each recipe level (procedures, unit procedures, and operations)
is considered an individual recipe. As such, the components that make up a recipe
are defined for each level. This lets you:

• Reuse operations in multiple master recipes.

• Execute unit procedures or operations individually, as you might do with a
Clean In Place operation.

A Batch Execution recipe consists of the following parts:

Header – contains all administrative information for a recipe including the

name, version number, author, and the issue date. Batch Execution
maintains administrative information, including the recipe and product
names, the author's ID, area model name, origin and verification dates,
and the default batch size.

Parameters – contains a list of process parameters such as mixing time or

temperature. In Batch Execution, each parameter is defined with the
Equipment Editor and is associated with a specific phase. Refer to the
Equipment Configuration Manual for information on defining process

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 Batch Execution and the ISA S88.01 Models

(phase) parameters, and refer to the Recipe Development Manual for

more information on working with parameters.

Equipment Requirements – defines a list of the equipment that is required to

produce a product. In the site and general recipes, this list is a general
guideline. In Batch Execution, the master recipe contains a set of
constraints to determine which equipment may produce the product. The
control recipe, created at run time, defines the specific equipment that
will be used to produce the batch.

Procedure – defines the process strategy. General and site recipes include
procedures based on the Process model. Master and control recipe
procedures are defined using the structure defined in the Procedural
model.

In Batch Execution, a procedure defines the unit procedures, operations,

and phases that are executed on the equipment specified in the recipe's
equipment requirements. In Batch Execution, each level of the procedure
is considered a recipe. This lets you reuse unit procedures and operations
in multiple procedures. Batch Execution also lets you create class-based
recipes that you can execute on any unit of the class defined in the
equipment requirements.

Production Planning and Scheduling

Production planning and scheduling creates the batch schedule used by Process
Management. Specifically, production planning and scheduling includes the
following functions:

• Developing and revising a production schedule.

• Determining equipment availability.
• Determining raw material availability.

Production Schedule

Batch Execution provides production planning at the recipe level, which allows you

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Application Guide

to schedule batches for production. You have two options for scheduling batches for
production:

• Operators or plant supervisors can add batches to the Batch Execution

Client's Batch List using the Add Batch command. Additionally, Batch
Execution supplies a BatchAdd ActiveX control from which operators can
add batches, as well as a BatchList control that provides similar
functionality to the Batch Execution Client's Batch List.
• Integrators can create a campaign manager using VBIS. VBIS lets you
create a custom application that interfaces with the Batch Execution Server
application. Refer to the Mastering Batch Execution section for more
information on developing custom applications using VBIS.

Equipment Availability

When using a class-based recipe in automatic mode, Batch Execution automatically

allocates resources to batches based on (1) the equipment requirements defined for
the recipe, (2) the equipment properties in the area model, and (3) the real-time
conditions on the plant-floor.

During batch execution, Batch Execution ensures that the equipment is available and,
if it is currently in use, does not allocate the unit to the batch until it is released by
the previous batch. To determine the availability of units, you can configure
UNIT_READY and UNIT_PRIORITY tags for units in the area model. Prior to
allocating a unit to a batch, Batch Execution checks the values of these tags to
determine which units are available. For more information on defining these tags,
refer to the Equipment Configuration Manual.

Raw Material Availability

There are several approaches that you can take to ensure that the necessary raw
materials are available to execute a batch. You can:

• Prompt operators to check ingredient availability prior to executing a batch.

• Before executing a step in a recipe, check the status of an iFIX tag that
monitors the amount of ingredient in a tank, for example.

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 Batch Execution and the ISA S88.01 Models

• Build a custom application using VBIS. Refer to the Custom Applications

manual for more information on using VBIS.

Process Management
Process management controls batches and resources within a process cell. Process
management consists of the following control functions:

• Manage batches by creating a control recipe from the master recipe based
on scheduling and equipment information.
• Manage process cell resources by allocating, reserving, and arbitrating
conflicts for the equipment required for batches.
• Provide batch and process cell information to Production Information
Management.

Batch Execution manages the manufacturing process by creating control recipes

from the master recipes that are scheduled for production. All the necessary
equipment entities are allocated, arbitrated, and controlled using the control recipes
and the arbitration information defined for the equipment.

Unit Supervision
Unit supervision ties the recipe to equipment control. The main control functions
performed as part of unit supervision include the following:

• Acquire the required units and execute operations.

• Manage unit resources for both the acquired unit and services provided by
other units.
• Collect batch and unit information including status changes and derived
values, for Process Information Management.

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Application Guide

In Batch Execution, the equipment requirements defined in the recipe procedure

determine which units a batch can use. For class-based recipes, the equipment
requirements also define how to select which unit instance to bind to a unit
procedure. During batch execution, Batch Execution allocates the selected units to
the batch. The operations, defined in the recipe procedure, are run on the allocated
units.

Process Control
Process control provides regulatory and discrete control at the unit, equipment
module, and control module levels. Process control provides the following control
functions:

• Executes phases by receiving parameters and commands.

• Executes basic control causing changes in equipment and process states.
• Collects data from sensors, derived values, and events that occur during
phase execution.
• Sends data to Production Information Management.

The Batch Execution Server performs supervisory control on the equipment

modules. Each equipment phase defined in the area model is tied to the equipment
module on which the phase executes. Requests and commands defined in the phase
control logic cause changes in equipment and process states.

Production Information Management

Production Information Management collects, stores, processes, and reports on
production information. This information can then be used in both batch and non-
batch related reporting and analysis. The primary focus of this activity, as related to
batch processing, is the ability to manage historical data. Managing the historical
data includes receiving and storing information, manipulating the data, and
producing batch reports.

Batch Execution uses Active Journaling™ to write batch event data, in real-time, to a
relational database. You can then access this data using your company's analysis
tools. Refer to the Reporting and Analyzing Production Data section for more
information on Active Journaling.

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 Batch Execution and the ISA S88.01 Models

Process Model
The Process model is a result of performing procedural control on the equipment in
the process. The Procedural Control model, when mapped to the equipment, provides
the processing functions described in the Process model. The relationships between
the Procedural Control model and the four lower levels of the Physical model that
produce the Process model are shown in the following figure. The process model
consists of the following levels:

Process – is the production of a batch using the available equipment. A process

consists of a procedure run on a process cell.

Process Stage – is a set of process operations. A process stage results from

performing a unit procedure on an equipment unit. A specific set of
operation instructions is included in the unit procedure. When a unit is
allocated for a particular batch, it executes the instructions using any
additional parameters passed to it at execution time.

Process Operation – consists of a set of process actions. A process operation

typically transforms material from one state to another. It can be achieved
by running an operation on a unit.

Process Action – is a minor processing task. A process action can be achieved

by running a phase on either a unit or an equipment module.

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Application Guide

Process, Procedural Control, and Physical Models Relationship

Linking a Control Recipe to the Equipment

In Batch Execution, a control recipe is linked to the equipment at the phase level.
Equipment phases are defined in the area model to represent each phase in the
process. A recipe executes the equipment phase, which in turn is tied to the physical
equipment on the plant floor and the phase logic in the process controller. The
following figure illustrates this relationship.

36
 Exploring the Sample Application

Linking the Recipe Procedure to the Equipment

Exploring the Sample Application

Batch Execution supplies a sample project based on a virtual plant that makes
toothpaste. This plant manufactures several flavors of baking soda toothpaste. It does
this by creating a baking soda base mixture and an additive mixture that are
combined together in a reactor. The toothpaste is then packaged in tubes and pump
bottles.

The Batch Execution documentation uses this application to explain Batch Execution
concepts and to provide detailed examples. You can use the demo as a reference
when developing your own Batch Execution application. Use the demo project to
explore Batch Execution from the development to the production stages of a batch
manufacturing environment, including:

37
Application Guide

• A sample area model representing the plant-floor equipment.

• Sample recipes to produce multiple flavors of toothpaste.

You can open the sample project from the Proficy Batch Execution WorkSpace. The
project files, by default, are installed into C:\Program Files\GE Fanuc\Proficy Batch
Execution\PROJECTS.

Designing the Toothpaste Control Strategy

Before you can implement any batch application, there are several planning and
design tasks to consider. These include:

• Outlining the general procedure required to manufacture the product.

• Identifying the process flow.
• Partitioning the plant equipment.
• Defining the equipment requirements.

The following subsections describe these tasks for the sample toothpaste application.

When you have completed the design strategy for implementing Batch Execution,
you can begin equipment and recipe development. These tasks are described in the
Developing a Batch Execution Project section.

Outlining the General Procedure

The general steps required to make a batch of toothpaste are outlined below.

To make a batch of toothpaste:

1. Add raw material ingredients that comprise the base of the toothpaste into a
mixer. The raw material ingredients are baking soda, fluoride, gum,
alkaline, and water.
2. Add raw material ingredients that comprise the flavor of the toothpaste into
a mixer. The possible flavors are wintergreen, spearmint, peppermint, and

38
 Exploring the Sample Application

bubble gum. All flavors also require a whitening agent.

3. Agitate the base ingredients at a specified speed and duration. While
agitating, cool the mixture to a specified temperature.
4. Agitate the flavor ingredients at a certain speed for a specified duration.
5. Test the pH value for the base mixture. If the test results are not within
tolerance, add corrective ingredients.
6. When both the base and flavor mixtures are complete, transfer the mixtures
into the reactor.
7. Agitate the mixture in the reactor at a specified speed and duration. While
agitating, aerate the mixture.

Identifying the Process Flow

Identifying your application's process flow is the first step in automating your plant.
A process flow diagram provides a high-level view of your process that groups
related process functions.

Partitioning Plant Equipment

In addition to identifying the process flow, you also need to partition your plant
equipment. Partitioning your equipment for maximum efficiency is the key to
successfully automating your plant. Typically, a Process and Instrumentation
Drawing (P&ID) is used to identify and partition the equipment used in a process.
The following figure shows the P&ID for the sample toothpaste application.

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Application Guide

Sample Toothpaste Application P&ID

40
 Exploring the Sample Application

Equipment Requirements
The production facility contains one process cell consisting of several production
lines. Based on the production requirements of the flavored toothpaste process, a line
must include:

• Seven tanks to hold raw materials

• Two mixers
• One reactor
• Pipes and valves required to transport solutions

Based on the P&ID in the Sample Toothpaste Application P&ID section, you can
divide the process cell into several production lines. Depending on how the recipe is
configured, either the operator or Batch Execution can choose the production line
based on what mixers are currently available.

Other Samples
In addition to the Sample Application, Proficy Batch Execution provides other
samples for:

• ActiveX Controls – HTML, Visual Basic, and Visual MFC sample projects
that you can use to build and test the Proficy Batch Execution ActiveX
controls.
• VBIS – Sample applications that demonstrate the VBIS API, a sample
campaign manager that uses VBIS, and an EWI Test.
• PLIs – Sample PLI ladder logic for the following programmable
controllers:
• The Allen-Bradley™ PLC5 Series (PLI_REV2_06.RSP). This
PLI was written in RSLogix™ 5.
• The Allen-Bradley™ SLC/500 (PLI_REV2_06.RSS). This PLI
was written in RSLogix 500.

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Application Guide

• The Allen-Bradley™ ControlLogix Processor

(PLI_REV4_00.ACD). This PLI was written in RSLogix 5000.
This sample uses Data Structures or Direct Addressing. It does not
use PLC-5 addressing (recommended), and instead uses RSLinx as
an OPC Server providing information directly to Batch Execution.
• The Allen-Bradley™ ControlLogix™ Processor
(PLI_REV2_06.ACD). This PLI was written in RSLogix 5000.
The sample provides a more robust communications method using
Allen-Bradley driver and RSLinx™ through Proficy iFIX as
opposed to OPC directly to RSLinx.
• The Siemens S7-300 and S7-400 PLCs (S7_pli_6.zip). This PLI
was written with Siemens Step 7 Series software.
• WorkInstruction – Demo project (EWIDemo.wkb) that demonstrates how
to use the WorkInstruction feature. It includes two sample EIBs and a
Microsoft SourceSafe database that is installed along with the product.
Refer to the section WorkInstruction Demo Project section for more
details.

You can find the samples of the ActiveX controls, VBIS, and the in the c:\Program
Files\GE Fanuc\Proficy Batch Execution\samples folder, if you installed Proficy
Batch Execution to the default location. The WorkInstruction demo project,
EWIDemo.wkb, is located in the Program Files\GE Fanuc\Proficy Batch
Execution\projects folder. The SourceSafe database is located in the Program
Files\GE Fanuc\Proficy Batch Execution\projects\EWIDemo\EWISS folder.

Developing a Batch Execution

Project
The sections that follow discuss the development tasks in Batch Execution and how
they are implemented for the sample toothpaste application:

• Development Overview
• Developing a Batch Execution Project

42
 Developing a Batch Execution Project

• Programming the Process Controller

• Configuring the Area Model
• Developing Recipes
• Storing Recipes in the Relational Database
• Using the Batch Execution Soft Phase Server
• Developing iFIX Pictures

Development Overview
As the picture illustrates in the Developing a Batch Execution WorkSpace Project
section, developing a Batch Execution application consists of several tasks. Before
you can begin any development, you must first have a solid control strategy in place.
Refer to the Exploring the Sample Application section for information on designing
a control strategy. Once this strategy is in place, you can begin implementing Batch
Execution for your application.

The following sections discuss each Batch Execution development task.

Reporting and Analyzing Production Data

Accurate and timely reporting capabilities are critical to tracking your facility's
production data. This is especially important for food and chemical facilities that
need to meet regulatory agency requirements.

You can integrate Batch Execution data with other areas of the manufacturing
enterprise. Because the data is stored in a relational database, you can update your
enterprise data with Batch Execution data so you always have the latest plant
production information available.

The sections that follow discuss the reporting options provided in Batch Execution
including:

• Active Journaling

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Application Guide

• Archiving process values

• Proficy Plant Applications Batch Analysis Reports

Active Journaling
To satisfy all your reporting requirements, Batch Execution provides Active
Journaling. Active Journaling is the process of recording event data in a relational
database. The following figure illustrates the Active Journaling architecture.

Active Journaling Architecture

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 Developing a Batch Execution Project

Batch Execution lets you configure the types of batch data to archive by providing
filtering capabilities. Typically, you will want to configure Batch Execution to
archive actual process values. Typical process values include:

• Total amounts produced

• Actual temperature values
• Actual ingredient amounts

Batch Execution does not limit the information you can archive. You can configure
your system to report on any value that is important to your process.

For more information on configuring the Batch Archiver, refer to the System
Configuration Manual.

Archiving Process Values

To archive process values, you can configure phase reports for each value that you
need to archive. Phase reports are parameters that store actual process values or
batch values used by the equipment phase. Batch Execution uploads this information
from the phase logic in the process controller to the Batch Execution Server after the
phase completes. The Batch Execution Archiver can then archive the reports to the
relational database.

For example, when a batch of toothpaste completes, you may want to report the
actual amount produced.

To report the amount of toothpaste produced in the example:

1. Configure a phase report to report the value of the Reactor's tank level
indicator, LI501.
2. Construct the recipe so that the phase report is included in the final step of
the recipe procedure. In the sample toothpaste application, the final phases
to execute are the AGITATE and AIR phases, in parallel. In this case, you
can configure either phase to include the report parameter.
3. Configure the Archiver to archive reports to the relational database.

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Application Guide

The following figure illustrates this scenario.

Archiving Process Values to a Relational Database

Proficy Plant Applications Batch Analysis Reports

The Proficy Batch Execution product includes support for Proficy Plant Applications
Batch Analysis Reports. These reports provide information on your S88.01 batch
data. With Proficy Plant Applications Batch Analysis Reports you can:

• Compare cycle times, parameters and variables across batches.

• Report and summarize batch data in support of improvement initiatives.
• Trend related parameters across batches to understand and control process
variation.
• Combine quality, production tracking and other core manufacturing
functions with batch operations providing a complete picture of plant
operations.

To support the Proficy Plant Applications Batch Analysis Reports, Batch Execution

46
 Developing a Batch Execution Project

includes the BATCHANALYSIS table. This table collects batch event data for use in
the reports.

NOTE: The Proficy Plant Applications product (which includes the Batch Analysis
Reports module) supports SQL Server databases. Importing Batch Execution data
from an Oracle database into a Batch Analysis Report is not supported.

For more information on configuring Batch Execution to support Proficy Plant

Applications Batch Analysis, refer to the System Configuration manual. For
information on configuring Proficy Plant Applications Batch Analysis, refer to the
Plant Applications Batch Analysis documentation.

Developing a Batch Execution WorkSpace Project

The Proficy Batch Execution WorkSpace is the starting point for using Batch
Execution and is where the majority of the developers' time is spent. The Proficy
Batch Execution WorkSpace provides an integrated and flexible environment to
develop and configure projects. A project is the entire set of items needed to deliver
a batch solution.

The sample toothpaste application contains the following GE Fanuc Batch Execution
project items:

• Configuration files
• Area model
• Recipes
• Embedded OLE-compliant documents

Similar to the Microsoft Explorer, the Proficy Batch Execution WorkSpace organizes
a project into folders. Each folder stores the common types of items in a project, such
as pictures, configuration files, and recipes. Each item is associated with a folder.
This makes locating an item as simple as opening the associated folder.

The following figure illustrates each Batch Execution development task. Notice that
you can perform most development tasks in parallel. However, it is important that all
members of your development team have a clear understanding of the design

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Application Guide

specifications for your system.

Batch Execution Development Task Overview

Embedding OLE Documents

The Proficy Batch Execution WorkSpace is object linking and embedding (OLE)
compliant. This means that you can integrate documents from other OLE-compliant
programs, such as Word and Excel, in one easy step. This feature allows you to work
on a Word document or an Excel workbook directly from the Proficy Batch
Execution WorkSpace. For example, you may want to link your design specifications
or schedules to a project. This way, they are readily available for you to reference at
any time.

48
 Developing a Batch Execution Project

Like Batch Execution project items, the documents from OLE-compliant programs
appear in the work area that the Proficy Batch Execution WorkSpace supplies when
you create or edit them.

Using the Proficy iFIX WorkSpace

As an alternative to developing a project in the Batch Execution WorkSpace, the
entire Batch Execution project can be developed and maintained through the Proficy
iFIX WorkSpace. The Proficy iFIX WorkSpace serves as a single development
environment for both iFIX and Batch Execution. You can access the Batch
Execution books, Batch Execution Configuration dialog box, Batch Execution
equipment, and recipes from the iFIX WorkSpace tree, as shown in the following
figure.

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Application Guide

Batch Execution Entries in the Proficy iFIX WorkSpace Tree

Programming the Process Controller

There are two areas of development when programming your process controller:

• Programming the Phase Logic Interface (PLI).

• Programming the phase logic.

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 Developing a Batch Execution Project

The figure in the Understanding the PLI section illustrates the relationship between
these two areas.

Note that the sample application is not tied to real I/O. Instead, it uses the Soft Phase
Server OPC Simulator.

Understanding the PLI

The PLI is the standard interface between the Batch Execution Server and the phase
logic. The PLI is the Batch Execution-specific portion of the phase and controls the
state transitions for phases. Phases in Batch Execution must follow a specific state
transition path. This path is based on the state transitions outlined in the ISA S88.01
Batch Control Standard.

For more information on programming the PLI, refer to the PLI Development
Manual.

Programming the Process Controller

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Application Guide

Understanding the Phase Logic

The phase logic contains the instructions to sequence the individual pieces of
equipment connected to the physical devices. It is the code that contains the control
steps, such as opening a valve, starting a pump, or stopping a totalizer. How you
program your phases depends entirely on your process. However, you can implement
design techniques to make your phase logic modular, generic, and maintainable.

For more information on programming and designing phase logic, refer to the Phase
Programming Manual.

Programming Requests

Batch Execution provides a series of request functions that enable the phase logic to
request the Batch Execution Server to perform specific actions, such as downloading
phase parameters and uploading phase report values.

For example, you may have an Agitate phase that requires a value to set the mixer
speed. In this case, you can program a Download Parameter Request in the Agitate
phase logic to download the mixer speed parameter value.

For more information on programming requests into your phase logic, refer to the
Phase Programming Manual.

Configuring the Area Model

The area model provides a graphical, hierarchical representation of the process
equipment in your plant. This database is then used by other areas of Batch
Execution to build recipes and execute batches. Once the area model is configured, it
is unlikely that it will require major changes. It may require some maintenance from
time-to-time, if you modify the process equipment on the plant floor.

Based on the equipment requirements outlined in the Exploring the Sample

Application section, the following equipment is defined for the sample application.
The figure that follows illustrates a sample equipment configuration.

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 Developing a Batch Execution Project

Area
The sample application's equipment is contained in an area called Area1. This is the
default area name provided by Batch Execution.

Process Cell
Within Area1 is one process cell called Toothpaste. This process cell contains all the
equipment required to produce a batch of toothpaste.

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Application Guide

Sample Application Equipment Configuration

Unit Classes
The toothpaste process cell in the sample application contains three unit classes:

• A Raw unit class is defined for seven similar storage tanks.

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 Developing a Batch Execution Project

• A Mixer unit class is defined for three similar mixers.

• A Reactor unit class is defined for two similar reactors.

Unit Instances
Instances of each unit class are created to represent each physical unit in the process
cell. Each unit instance inherits its unit class properties, including any unit tag
classes defined for the unit class. At the instance level, properties such as the
equipment ID and unit tags are defined based on the unit's physical properties. The
previous figure with the sample equipment configuration illustrates each unit
instance defined for the sample application and their associated unit classes.

Standard Equipment Phases

Standard equipment phases configured in the Equipment Editor are equipment-
centric, meaning that you are not defining the control logic for the phase, you are
configuring the equipment module on which the phase executes. The actual control
logic for the phase resides in the process controller, not in the Equipment Editor.
This type of phase is called a standard equipment phase.

Your task in the Equipment Editor is to create a representation of each equipment

phase in the process controller and tie it to the equipment on which the equipment
phase executes. In order to do this, you must have a complete understanding of how
the equipment phases are programmed in the process controller. The previous figure
with the sample equipment configuration illustrates each unit instance defined for the
sample application and their associated unit classes and equipment phases. There are
no Batch Direct phases in the sample application.

Batch Direct Equipment Phases

With Batch Direct phases, the PLI logic is built directly into the phase. This PLI
logic provides a standard interface between the Batch Execution Server and the
equipment phase. What that means, is that you can use batch direct phases to directly
communicate with existing PLC programs located on your process controllers,
without having to rewrite any additional PLI logic. With Batch Direct phases, you
have a simpler interface to the process controller.

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Application Guide

Your task in the Equipment Editor is to create a representation of all equipment

phases (standard and Batch Direct) and tie it each phase to the equipment on which it
executes. In order to do this for Batch Direct phases, you must have a complete
understanding of how the phase logic is used on the process controller.

Developing Recipes
The general procedure (outlined in the Exploring the Sample Application section) is
translated into a master recipe procedure called Make_Toothpaste. This procedure is
illustrated in the Using Class-Based Recipes section.

Recipe development is generally an ongoing process. As you enhance your products,

you need to modify recipes to incorporate new production requirements. The sample
toothpaste recipes are designed with this requirement in mind. It does this by
incorporating the following Batch Execution features:

• Active Binding™
• Recipe parameters
• Class-based recipes
• Parallel Processing

The following sections describe each feature and how it is used to meet the
requirements of the sample toothpaste application. For additional information on any
of these features, refer to the Recipe Development Manual.

Using Active Binding

Requirement:

Maximize the plant's equipment usage.

Solution:

Batch Execution provides Active Binding. Active Binding allows you to bind and re-

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 Developing a Batch Execution Project

bind unit procedures to units at multiple stages in a batch's life cycle, including when
a batch is created or in production. Recipe authors can configure recipes to
automatically allocate equipment to batches based on (1) the properties of the
equipment model, and (2) the real-time conditions on the plant floor. Refer to the
Mastering Batch Execution section for more information on Active Binding.

Using Recipe Parameters

Requirement:

The general procedure requirement for the toothpaste application is to manufacture

several flavors of toothpaste.

Solution:

Batch Execution lets you create recipe parameters to define the amount of each
ingredient required for the types of toothpaste in production. By varying the amount
of each ingredient, different types of toothpaste are made with the same master
recipe. For example, to make mint-flavored toothpaste, the parameter MINT is set to
60. To make regular-flavored toothpaste, MINT is set to 0.

Using Class-Based Recipes

Requirement:

The toothpaste application must be able to select the equipment on which the recipe
executes based on which units are available when the batch is scheduled for
production.

Solution:

Batch Execution lets you build class-based recipes that allow the BASE and
ADDITIVE unit procedures to use any mixer defined in the process cell. This feature
lets you create recipes that are not tied to a specific piece of equipment. Furthermore,
you can configure the equipment requirements for the BASE and ADDITIVE unit
procedures to automatically bind units to these procedures during batch execution.

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Application Guide

Make_Toothpaste Procedure

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 Developing a Batch Execution Project

Parallel Processing

Requirement:

The requirements of the general procedure state that the base mixture must be
agitated and cooled simultaneously.

Solution:

Batch Execution lets you perform parallel processing simply by constructing the
recipe's sequential function chart to do so. In the MAKE_BASE operation, the
AGITATE and COOL phases run in parallel. When both phases are complete,
control moves to the QA_TEST phase for testing.

Storing Recipes in the Relational Database

Batch Execution can store recipes in both file-based and SQL-based formats. The
storage type is set at the project level, meaning that all recipes within a project must
be stored in either SQL or file format. It is transparent to the recipe parameter or
whether the recipe is file-based or SQL-based; the recipes are built in the same
manner. Batch Execution handles the storage type internally.

Batch Execution stores and retrieves recipe data based on the Batch Execution
Logical Data model. The Logical Data model is the table structures and rules that
represent the storage of Batch Execution recipes in a relational database.

If you plan to store recipes in the relational database, developers need to consider the
following:

• Recipe storage types are set at the project level, meaning that all recipes
within a single project must be either SQL-based or file-based.
• Configure the recipe tables in your relational database. Batch Execution
provides scripts that build these tables for you.
• Configure a data source so that Batch Execution knows where to store and
retrieve the recipe data.

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Application Guide

For more information on storing recipes in a relational database, refer to the Recipe
Development Manual. For more information on configuring the Logical Data model
in your relational database, refer to the System Configuration Manual.

Using the Batch Execution Soft Phase Server

The Soft Phase Server is an OPC Server that acts as a PC-based controller between
the Batch Execution Server and soft phases. Soft phases are Batch Execution phases
whose phase logic is provided by scripting or programming outside of a hardware
controller (PLC or DCS) environment. You can implement soft phases either within
iFIX or with any development systems that supports OLE Automation servers and
OLE for Process Control (OPC), including Visual Basic, C++, or Java. In every case,
communication between the Soft Phase Server, the Batch Execution Server, and the
phase logic is accomplished using OPC.

Soft phases use the phase logic as described in the Phase Programming Manual.
Implementation of the PLI, that is normally part of the hardware controller, is part of
the Soft Phase Server. Refer to the PLI Development Manual for detailed
information on PLI.

During the development stage, you can model and test your equipment configuration
and recipes using the Soft Phase Server in Simulation Mode. With the Batch
Execution Soft Phase Server, you can build an area model and tie the equipment
entities to the Batch Execution Soft Phase Server simulated points, rather than actual
I/O points. After you build the recipes and area model, you can then simulate
production by executing batches. Only 50 parameters, 50 reports, and 50 request
qualifiers per phase are supported.

NOTE: You must configure each phase in the Soft Phase Server to run in Simulation
Mode if you want to use the Soft Phase Server as a simulator.

The Batch Execution Soft Phase Server uses your equipment phases and related
parameters to simulate your batch operation. Specifically, you can use the Batch
Execution Soft Phase Server to:

• Test phase configuration and synchronization.

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 Batch Execution Operations

• Test new recipes.

• Determine how long batches will run.

For more information on using the Batch Execution Soft Phase Server refer to the
Batch Execution Soft Phase Server online help or Configuring the Soft Phase Server
in the System Configuration Manual.

Developing iFIX Pictures

Incorporating iFIX pictures into your system requires an initial investment in time to
design and create each required picture. However, the results of those efforts are
pictures that can provide a range of views into the batch processing environment,
from an overview of a plant's operations to a detailed representation of a specific
piece of equipment.

For example, in the sample toothpaste application, you might want to use iFIX
pictures for the following:

• A plant overview picture.

• A line control picture.
• Unit control pictures for both the mixer and the reactor unit classes.
• Batch status picture that lets operators monitor batches from outside the
Batch Execution Client.

Refer to the Creating Pictures manual for more information on iFIX pictures.

Batch Execution Operations

The sections that follow discuss the operations tasks in Batch Execution. You can
explore these tasks using the sample recipe procedure, Make_Toothpaste, provided
in the Proficy Batch Execution WorkSpace demo project.

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For additional information on Batch Execution operations, refer to the Operations

Manual.

Operations Overview
Batch Execution provides operators with the following environments for controlling
batches:

• Nine graphical screens in the Batch Execution Client application.

• The ability to incorporate iFIX pictures into your operations environment.
• A set of ActiveX controls that you can:
• Embed directly into iFIX pictures, web browsers, or any OLE
compliant container.
• Incorporate into iFIX pictures (using the Runtask command).

The following figure illustrates the operations tasks and the order in which they are
performed.

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 Batch Execution Operations

Operations Task Overview

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Application Guide

Understanding Batch Execution

The Batch Execution Server controls the execution of a batch based on the phase
state transition logic in the Phase Logic Interface (PLI). The purpose of the PLI is to
control the transitions between the phase states.

The PLI is the standard interface to the project-specific phase logic. The PLI receives
commands from the Batch Execution Server or the operator and then initiates the
different components of the phase-specific control logic. This communication flow,
shown in the following figure, ultimately controls the execution of a batch.

Batch Execution Communication Flow

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 Batch Execution Operations

Understanding States
Batch execution follows a series of state transitions. These transitions are based on
the procedural states defined in the ISA S88.01 Batch Control Standard.

The batch state and the states of phases running within a batch are updated as a batch
progresses. These states are displayed in several locations in the Client; every screen
has either a field or a column where the state information is visible.

An operator can only issue commands that are valid for the current state. For
example, if a batch is in the Running state, the operator can issue several commands
including Stop, Abort, and Hold.

The following figure illustrates the valid state transitions paths.

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Application Guide

Valid State Transition Paths

Controlling and Monitoring Batches

Batch Execution provides several options for controlling and monitoring batches.
The Batch Execution Client provides nine graphical screens that operators can use to
perform the following tasks during batch production:

• Create and start batches.

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 Batch Execution Operations

• Bind and rebind equipment to batches. Depending on how the recipe was
configured, Batch Execution can (1) prompt the operator to select a unit to
allocate to a unit procedure, or (2) automatically bind unit procedures to
units. Given the appropriate rights, operators can rebind unit procedures to
units during batch production.
• Monitor a batch as it executes from a variety of viewpoints. The most
popular is the SFC View screen, which graphically displays a batch as it
executes each step.
• Issue commands such as Stopping, Holding, Aborting, and Restarting
batches.
• View batch journal data for the current batch and for previous batches.
• Acknowledge operator prompts, binding prompts and transition breakpoint
prompts.
• Control individual phases.
• Arbitrate resources.
• View alarms.

Using the ActiveX Controls

As an alternative to using the Batch Execution Client, Batch Execution supplies a set
of ActiveX controls that you can use to control and monitor batches. The ActiveX
controls included with Batch Execution are as follows:

• BatchList
• BatchAdd
• BatchRecipeList
• BatchOperatorPromptsList
• BatchBindingPromptsList
• BatchAlarmList
• BatchManualPhase
• BatchSFC

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Application Guide

• BatchActivePhaseList
• BatchCampaignManager

WorkInstruction includes the following control:

• EWI ActiveX control

These controls can be run from the following containers:

• iFIX Run-time environment

• Any ActiveX or OLE container, such as web browsers or Visual Basic

Additionally, you can incorporate the ActiveX controls into an iFIX picture using the
Runtask command. To do this, first place the control into a container application,
such as a Visual Basic form, and save it as an executable (EXE). Then, use the
Runtask command in iFIX to run the executable.

The controls contain most of the same functionality provided in the corresponding
view in the Batch Execution Client. The following figure shows an example of the
BatchList Control supplied with Batch Execution.

BatchList ActiveX Control

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 Batch Execution Operations

Developing VBIS Applications

In addition to the Batch Execution Client and the ActiveX controls, you can use
VBIS to develop custom applications. For example, you can develop VBIS
applications to:

• Create a campaign manager. VBIS provides a scheduling function that lets

you automate the process of adding batches to the Batch List in the Batch
Execution Client. In this way, you can integrate your corporate scheduling
system into Batch Execution so that your production schedules are always
up-to-date.
• Automate the process of starting batches. VBIS provides a function
containing all the necessary parameters for binding equipment and
specifying parameter values. This is the mechanism that external programs
can use to control batch execution.
• Develop a custom VBIS application that monitors the state of batches. By
polling the Batch Execution Server for the current batch state, your custom
application can determine when a batch completes. This technique is useful
in many types of applications, such as a campaign manager.

These are just a few examples of VBIS applications. You can develop numerous
VBIS applications to suit your particular needs.

Refer to the Custom Applications manual for more information on VBIS.

Using the Campaign Manager

The Campaign Manager provides a simple way for you to manage batches associated
with a campaign. A campaign is the execution of multiple, similar batches, which are
typically required to fill a process order; process orders are orders where one or more
customer orders are grouped together by product and assigned to specific production
equipment. The Campaign Manager creates a campaign with parameters you
provide. It determines the number of batches required to satisfy an order, and creates
and schedules the batches necessary to satisfy campaign order requirements. After
creating campaigns, you can use the Campaign Manager to monitor campaigns and
their individual batches.

The Campaign Manager offers electronic signature capability, allowing you to

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Application Guide

provide user authentication prior to execution of a command. It also allows you to

restrict access to features by user, such as the ability to create or remove campaigns.

The Campaign Manager has three components – the Campaign Client, the Campaign
Server, and the Campaign Database. The Campaign Client is an ActiveX control
that, when hosted in an ActiveX container, provides you with an interface to create
and manage campaigns. The Campaign Server is a service that runs in parallel with
the Batch Server and controls the triggering and execution of campaigns. The
Campaign Database provides storage for the campaign data.

For more information on Campaign Manager, refer to the Campaign Manager guide
and the Custom Applications manual.

Mastering Batch Execution

The sections that follow provide an overview of some of the more advanced features
in Batch Execution. Understanding how to implement these features can help you get
the most from your Batch Execution system. The following topics are covered:

• Understanding Active Binding

• Implementing a Class-Based Design
• Understanding Phase Synchronization
• Extending Batch Execution with VBIS
• Using Electronic Signatures
• Understanding Audit Versioning

Using Proficy Plant Applications Batch Analysis

Reports
You can import your Batch Execution event data into Proficy Plant Applications
Batch Analysis Reports. If you use the Proficy Plant Applications Batch Analysis

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 Mastering Batch Execution

product with Batch Execution, the following events would be part of a Batch
Analysis report:

• Active Binding
• Param Download Verify
• Prompt
• Recipe Header
• Recipe Value
• Recipe Value Change
• Report
• State Change
• State Command
• Step Activity

These events are listed in the Batch Execution Configuration dialog box, in the
Archiver tab, under Event Filters. You can access the Batch Execution Configuration
dialog box from the Batch Execution Workspace by double-clicking the Batch
Execution Configuration in the WorkSpace tree. You can also double-click the Batch
Execution Configuration in the Proficy iFIX WorkSpace tree to view this dialog box.

For information on how to configure Batch Execution to use Proficy Plant

Applications Batch Analysis Reports, refer to the Plant Applications Batch Analysis
Reports Configuration section in the System Configuration manual.

For steps on how to configure the Proficy Plant Applications Batch Analysis product,
refer to the Plant Applications Batch Analysis documentation.

Understanding Active Binding

To get maximum productivity from your equipment, Batch Execution supports
Active Binding. Active Binding allows you to automatically bind a unit procedure to
a physical unit. Batch Execution can bind units at batch creation and re-bind units
during batch production.

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Implementing Active Binding spans several areas of Batch Execution, including:

• Configuring the area model for Active Binding.

• Configuring recipes for Active Binding.

Configuring Active Binding in the Area Model

To provide Batch Execution with sufficient information to intelligently select an
appropriate unit, you can configure the following in your area model:

Equipment pathing – Within a process cell, you can specify the physical
connections between units. These connections are graphically represented
with connection lines. When the batch procedure executes, each selected
unit must be within a valid equipment path.

Equipment capacity – For each unit, you can specify the unit's maximum
capacity. When the recipe executes, the selected unit must meet the
capacity requirement defined for the unit procedure.

Equipment status tags – For each unit, you can specify a Unit Ready status and
a Unit Priority status, to indicate the unit's current availability and priority
rating. When the recipe executes, the unit selected by the Batch Execution
Server must be available, as defined by its Unit Ready tag. If more than
one unit is ready and available, the Batch Execution Server selects the
unit with the highest priority, as defined be the unit's Unit Priority tag.

These dependencies are optional, meaning that Batch Execution can automatically
allocate units if none of these dependencies are configured. However, to take full
advantage of Active Binding, you most likely will want to provide Batch Execution
with as much information as possible to make the most intelligent selection when the
recipe executes. For example, if unit capacity is important to your process, you
should configure equipment capacity to ensure that appropriate units are allocated to
batches.

Active Binding Configuration Based on Priority or Availability

You can allocate the units based on availability, the default setting for Active

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 Mastering Batch Execution

Binding. Or, you can allocate the units based on the unit priority tags (in the PLC,
Soft Phase Server, PDB, and so on). You configure this information from the
WorkSpace in the Batch Execution Configuration dialog box, under the Server tab.

Configuring Active Binding in Recipes

In the equipment requirements for your recipes, you can specify how you want Batch
Execution to bind batches to equipment (units). This includes the ability to
automatically bind batches to units.

Batch Execution provides three choices for binding equipment to recipes:

Automatic binding – this method allows the Batch Execution Server to select
the unit to bind to the unit procedure at run time based on criteria defined
in both the unit procedure and in the area model.

Operator prompt – this method prompts the operator to select a unit or to

specify an automatic selection just before the unit procedure runs.

Specify at Batch Creation – this method requires the operator to select a unit to
bind to the unit procedure when the batch is added to the batch list.

Additionally, you can assign operators rights to modify the binding at batch creation,
during batch execution, or both.

You can incorporate the following features into your recipes to provide the Batch
Execution Server with additional information to select units:

Jacobson Links – indicate whether the units used for two unit procedures must
be physically connected. Jacobson Links are connections that are drawn
within a recipe's sequential function chart (SFC) that represent a
necessary physical connection between unit procedures.

Forced Binding – indicates whether two unit procedures must run on the same
unit or must run on different units.

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Application Guide

Unit Procedure Capacity – indicates the amount of material the selected unit
must be able to transfer, process, or contain to run the unit procedure.
This value can be scaled with the batch scale.

Example: Active Binding Area Model Configuration

The equipment configuration for the sample toothpaste application takes advantage
of equipment pathing, equipment capacity, and equipment status to provide Batch
Execution with data to ensure that suitable units are allocated to batches.

Equipment Pathing

Configuring equipment paths ensures that the units selected for a batch are within a
valid execution path. The equipment pathing is based on the physical connections
that exist between units on the plant floor. In the sample application, the following
physical connections are configured:

1. The base ingredients (water, baking soda, gum, fluoride, and Ph_additive)
are on one header feeding MIX1, MIX2 and MIX3.
2. The additive ingredients (flavoring and whitener) are on a second header
that feeds into MIX2 and MIX3.
3. All three mixers feed into the REACTFLAVOR unit, while the
REACTPLAIN unit is fed only by MIX1.

The following figure illustrates the equipment pathing configured for the sample
toothpaste application.

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Sample Execution Path

Unit Capacities and Statuses

The following table lists the equipment capacity settings and the current equipment
status for each unit instance in the MIXER class.

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Application Guide

Sample Capacities and Status for the MIXER Unit Class

Unit Instance Capacity Amount Current Equipment Status

MIX1 1000 Liters MIX1_READY=0

MIX1_PRIORITY=0

MIX2 2000 Liters MIX2_READY=0

MIX2_PRIORITY=0

MIX3 500 Liters MIX3_READY=0

MIX3_PRIORITY=0

REACTPLAIN 1000 Liters REACTPLAIN_READY=0

REACTPLAIN_PRIORITY=1

REACTFLAVOR 2000 Liters REACTFLAVOR_READY=0

REACTFLAVOR_PRIORITY=2

Example: Active Binding Recipe Configuration

Coupled with the area model configuration, the Make_Toothpaste recipe procedure
shown in the following figure uses Jacobson Links™, forced bindings, and unit
procedure capacity requirements to ensure that suitable units are allocated to batches.

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Make_Toothpaste Recipe Procedure

Jacobson Links

The Jacobson Links, illustrated in the above figure, require that the units used by the
ADDITIVE and BASE unit procedures are physically connected to the unit that is
bound to the FINAL unit procedure.

Forced Bindings

The following table shows the unit procedure bindings that are configured for the
Make_Toothpaste procedure. In this case, the BASE and ADDITIVE units are forced
to run on different units.

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Sample Unit Procedure Bindings

Unit Unit Same Different

Procedure Procedure Units? Units?

BASE ADDITIVE No Yes

Equipment Requirements

Assume that the equipment requirements listed in the following table exist for the
BASE and ADDITIVE unit procedures in the sample application.

Sample Recipe Equipment Requirements

Unit Unit Capacity Bind Operator

Procedure Class Requirement Type Rights

BASE MIXER 1000 Liters Specify at Operator

Batch can modify
Creation binding
during
batch
execution.

ADDITIVE MIXER 200 Liters Specify at Operator

Batch can modify
Creation binding
during
batch

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Sample Recipe Equipment Requirements

Unit Unit Capacity Bind Operator

Procedure Class Requirement Type Rights

execution.

FINAL REACTOR 1000 Liters Specify at Operator

Batch can modify
Creation binding
during
batch
execution.

Example: Active Binding at Run Time

Assume that a batch is added to the Batch List in the Batch Execution Client for the
Make_Toothpaste recipe procedure. Based on the configurations and requirements
outlined above, the following sequence of events occurs:

1. Batch Execution selects the default unit for the FINAL unit procedure. For
this example, let's assume Batch Execution binds the REACTFLAVOR unit
to the FINAL unit procedure.
NOTE: You can modify the default unit at batch creation.

2. The operator starts the batch.

3. When both the BASE and ADDITIVE unit procedures are complete, the
FINAL unit procedure begins executing on the REACTFLAVOR unit.

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Implementing a Class-Based Design

Your main design goal when developing recipes is to create small, flexible
operations that can be reused and recombined in different ways. This approach
minimizes the number of operations you need to create and maintain while providing
you with the flexibility and power available in Batch Execution. For example,
instead of creating five custom operations for five different mixers, consider
designing one generic operation that can be used by the five mixers.

A class-based design lets you to develop recipes that can run on a class of units,
rather than a specific unit. Furthermore, you can configure these recipes for Active
Binding to maximize the use of your plant's equipment. Class-based recipes let you
develop flexible operations that you can reuse and recombine in different ways.
Implementing a class-based design requires that you configure the following:

• In the area model, configure unit classes, and then define each unit instance
with the class.
• When defining the equipment requirements for a recipe, specify that the
recipe is class-based. This indicates that the recipe can execute on any one
of the units within the specified unit class. You need to specify the default
unit as well.
• Use recipe parameters as placeholders for specific process values. A recipe
parameter is a variable that represents a process value. By including a
recipe parameter in an operation, you make it generic and reusable because
the recipe parameter acts as a placeholder for specific values. Recipe
parameters also override the hard-coded value in a phase and let you specify
any value you need depending on the batch in production. Once a value is
specified, the value is passed to a phase in the area model.

Refer to the Recipe Development Manual for more information on creating class-
based recipes and using recipe parameters.

Example: Class-Based Design

The sample toothpaste application uses a class-based design. Each recipe level has a
default unit, but it can run other units since it is class-based. The area model contains
three unit classes: RAW, MIXER, and REACTOR. The unit procedures in the

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Make_Toothpaste recipe procedure are configured as class-based recipes as follows:

• The BASE and ADDITIVE unit procedures can run on any unit in the
MIXER class. The MIXER class contains the MIX1, MIX2, and MIX3 unit
instances. The default unit for BASE is MIX1. The default unit for
ADDITIVE is MIX2.
• The FINAL unit procedure can run any unit in the REACTOR class. The
REACTOR class contains the REACTPLAIN and REACTFLAVOR units.
The default unit for FINAL is REACTFLAVOR.

During Active Binding, the Batch Execution Server selects the default unit or the
operator selects the unit based on the equipment requirements defined in the recipe
coupled with the equipment configuration defined in the area model. Refer to the
Understanding Active Binding section for more information on configuring recipes
and the area model for Active Binding.

Understanding Phase Synchronization

Depending on your needs, you may want one phase to communicate with another
phase. Typically, this happens when you need to synchronize the actions of both
phases.

In order for synchronized phases to run, all phases must be active simultaneously.
The first phase in the group sends a request to the Batch Execution Server. The
Batch Execution Server does not clear this request until the other phases in the phase
link group send requests to the Batch Execution Server, too. The Batch Execution
Server then clears all requests simultaneously.

Typically, you synchronize phases when transferring materials from one unit to
another. Configuring phase synchronization spans several areas of Batch Execution
development. Each task is described below:

• In the phase logic, program each phase in the synchronization group to:
• Send a message to each phase in the synchronization group.

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Application Guide

• Wait for messages from each phase in the synchronization group.

When all phases have sent and received messages from all other
phases in the synchronization group, the phases are synchronized.

• During equipment configuration, for each phase in the synchronization

group:
• Specify the number of phase partners. Phase partners identify the
number of phases with which the phase can communicate
simultaneously.
• Depending on the type of request, you may need to increment the number of
phase requests to account for the Send Message and Wait or the Receive
Message request that is programmed in the phase logic. For example,
entering 1 as the number of requests creates a phase tag called
PHASE_Q01, entering 2 creates two phase tags, PHASE_Q01 and
PHASE_Q02, and so on.
Refer to the Equipment Configuration Manual for more information on
configuring phases.
• During recipe development, create phase link groups to synchronize a group
of phases. A phase link group is a list of phases that communicate with each
other. Each phase can belong to different operations but they must reside in
the same procedure. Each phase in the link group must have the same
number of message partners.
Refer to the Recipe Development Manual for more information on phase
link groups.

Example: Phase Synchronization

The figure that follows illustrates an example of phase synchronization. In this
example, the material from the BASE and ADDITIVE unit procedures need to be
simultaneously transferred into the reactor before the FINAL unit procedure can
begin.

The unit procedures XFR_BASE and XFR_ADD each have phases called
XFR_OUT_LINK. These phases transfer material to the unit procedure
XFR_FINAL, which has a phase called XFR_IN_LINK. In order for the transfer to
be successful, these three phases must be synchronized with each other. The valves

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in the two XFR_OUT_LINK phases must be opened to transfer the material, and the
valve in the XFR_IN_LINK must be opened to accept the material.

For information on programming phases to perform phases for synchronization, refer

to the Phase Programming Manual.

Example of a Recipe that Synchronizes Phases

Area Model Configuration

In the area model for the example, each phase in the synchronization group is

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Application Guide

configured as follows:

Phase Class Number of Message Number of Request

Partners Tags

XFER_OUT_LINK 2 1

XFER_IN_LINK 2 1

The number of message partners is set to two because each phase must communicate
with two other phase instances. The number of request tags is set to one to account
for the Send Message request that needs to be programmed into the phase logic.

Recipe Configuration

To configure the phase synchronization for the recipe, do the following:

• Create the SFC for the Make_Toothpaste procedure that uses AND
structures for the XFER_BASE, XFER_FINAL, and XFER_ADD unit
procedures, which configures them to run in parallel.
• Configure forced bindings as follows:
• The BASE and XFER_BASE unit procedures must run on the
same unit.
• The ADDITIVE and XFER_ADD unit procedures must run on the
same unit.
• The FINAL and XFER_FINAL unit procedures must run on the
same unit.
• Create Jacobson Links to specify that the units allocated to the XFER_ADD
and XFER_BASE unit procedures must be physically connected to the unit
allocated to the XFER_FINAL unit procedure.

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• Create a phase link group that contains:

• The XFER_OUT_LNK phases for both the XFER_BASE and
XFER_ADD unit procedures.
• The XFER_IN_LNK phase for the XFER_FINAL unit procedure.

Phase Logic Configuration

To ensure that the XFER_OUT_LNK and the XFER_IN_LNK phases are in exactly
the proper state before they proceed, program the phases in your example to use the
Send Message and Wait request and the Receive Message request to synchronize the
three phases. This is illustrated in the following figure. The Send Message request
functions as the Master and the Receive Message request functions as the Slave
during phase synchronization.

Configuring the Phase Logic for Synchronization

As illustrated in previous figure, the XFER_IN_LNK phases and the

XFER_OUT_LNK phase synchronize the transfer of materials from one unit to
another in the example. Before the material is transferred:

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1. When the XFER_BASE unit procedure starts executing, the logic in the
XFER_OUT_LINK phase issues a Receive Message request to the Batch
Execution Server. The Batch Execution Server stores this in its message
queue.
2. When the XFER_ADD unit procedure starts executing, the logic in the
XFER_OUT_LINK phase issues a Receive Message request to the Batch
Execution Server. The Batch Execution Server stores this in its message
queue.
3. When the XFER_FINAL unit procedure starts executing, the logic in the
XFER_IN_LNK phase issues a Send Message and Wait request to the
Batch Execution Server.
4. The Batch Execution Server looks for the matching message ID in the
message queue.
5. The Batch Execution Server transfers the message values (if any).
6. The XFER_IN_LNK and both the XFER_OUT_LNK phases continue
executing and the material is transferred.

The following table lists the requests that are used to accomplish this
synchronization. Upon receiving the Receive Message request from the
XFER_OUT_LNK phase, the Batch Execution Server stores message ID 80 in the
message queue. Upon receiving the Send Message and Wait request from the
XFER_IN_LNK phase, the Batch Execution Server searches within the phase link
group for a match to message ID 80 in the message queue. When the message ID is
located, the Request register is cleared, and the phases are allowed to continue
executing.

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Phase Synchronization Requests

Phase Type of Request Description

Request Syntax

XFER_IN_LNK Send PHASE_RQ The XFER_OUT_LNK

Message = 5180 phase sends a message
and Wait ID of 80 to the Batch
PHASE_Q01
Execution Server.
=2
The phase waits for a
response from 2 phase
before continuing.

XFER_OUT_LNK Receive PHASE_RQ The XFER_IN_LNK

Message = 5580 phase waits to receive a
message ID of 80.

Extending Batch Execution with VBIS

Batch Execution is an open system that lets you integrate Batch Execution data with
multiple systems. VBIS provides a set of functions that allow third-party applications
to exchange information with and control Batch Execution without the use of the
Batch Execution Client. In addition, Batch Execution supplies a set of ActiveX
controls that you can incorporate into your custom applications.

For instance, using VBIS you can develop custom applications that can:

• Act as a campaign manager.

• Manipulate SQL-based recipes.

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Example

You might create a campaign manager by making VBIS interface calls that do the
following:

1. Schedule a batch.
2. Bind the units required by the batch.
3. Run a batch.
4. Enter a loop to request the current batch state.
5. When the state becomes complete, exit the loop and remove the batch from
the batch list.

For information on VBIS, refer to the Custom Applications manual.

Integrating Batch Execution with ERP Systems

You can configure Batch Execution to store batch data and recipes in a relational
database. This provides open access to your Batch Execution data and lets you
integrate this data into the planning areas of your manufacturing operation and your
Enterprise Resource Planning (ERP) system. Integrating all business areas of your
manufacturing enterprise, from the plant-floor to the corporate-level systems,
provides a single set of reliable data that you can use to make informed and timely
business decisions.

Integrating Batch Execution data with manufacturing systems can be accomplished

in several ways. Because the data is stored openly, in a relational database, you have
several options available to integrate the data.

The typical ERP integration path figure in the Using VBIS as an Integration Tool
section illustrates the ideal integration path. In this scenario, ERP and Batch
Execution data are stored in the same relational database. ERP data, including
inventory, general recipes, and schedules are stored in the ERP tables. Batch
Execution uses the relational database to store:

• Recipes in the tables comprising the VBIS Logical Data Model (LDM),
which is part of VBIS. The LDM is the table structures and rules that
represent the storage of Batch Execution recipes in a relational database.

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• Batch event data and transaction logs, by archiving the data to the relational
database.

Using VBIS as an Integration Tool

As the following figure illustrates, you can incorporate the functions provided by
VBIS to integrate Batch Execution data with your manufacturing enterprise data. For
example, you can use the Scheduling Service provided in VBIS to build a Batch
Execution campaign manager based on enterprise scheduling data. There are a
number of other interfaces provided by VBIS. For more information on using VBIS,
refer to the Custom Applications manual.

NOTE: A relational database is not required to use VBIS.

Typical ERP Integration Path

Storing the ERP and Batch Execution data in the same relational database allows
dynamic and immediate data reconciliation. For example, assume Batch Execution
produces a 2000 LB batch of toothpaste at Plant A. When the batch completes, Batch
Execution archives this amount to the relational database. The ERP system needs to
track production amounts for all plants. To update the ERP system, you can create a
table view to extract the batch amount from the Batch Execution data and join it to a
common location that the ERP system uses to send and retrieve current data. The

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following figure illustrates this scenario.

Using a Table View to Integrate Batch Execution Data

When the data is stored in separate relational databases, you can integrate the data by
writing a SQL program to query the Batch Execution and ERP data and then
reconcile the data.

Using Electronic Signatures

GE Fanuc originally introduced electronic signatures with the WorkInstruction
product. The Batch Execution product now also includes the electronic signature
capability in most ActiveX Controls, in the Batch Execution Recipe and Equipment
Editors (when used through the Batch Execution WorkSpace or launched
independently, outside of the WorkSpace), the Audit Reporter application, and the

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Electronic Signature tab of the Batch Execution Configuration screen.

With electronic signatures enabled, you can provide user authentication prior to the
execution of a Batch Execution command. The types of commands you can
authenticate against in the Batch Execution Editors include actions such as Startup,
Open, Save, Save As, Print, Export, Verify, and so on.

All signatures are authenticated using Windows security. What that means, is that an
operator must enter a valid user name and password from a Windows security group
to complete the command. You must create these groups and users with your
Windows software. Once created, you assign the commands and groups that you
want to authenticate against in your Batch Execution software.

You can configure commands to require none, one, or two signatures. If you
configure one signature, Batch Execution requires a Performed By signature from
the operator performing the command. If you configure two signatures, Batch
Execution requires a Performed By signature from the operator and a Verified By
signature from a supervisor to perform the command. If you enable electronic
signatures but do not configure either a Performed By and Performed By/Verified By
signature, Batch Execution captures the computer name and login name.

The following figure shows an example of an electronic signature displayed for the
Equipment Editor through the Batch Execution WorkSpace.

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Example of an Electronic Signature in the Proficy Batch Execution WorkSpace

Recipe Editor, Equipment Editor, and Batch Configuration

For the Batch Execution Recipe and Equipment Editors, you configure electronic
signatures for commands on a per node basis. Additionally, when you configure your
Batch Execution system, you can define electronic signatures to be required
whenever a user opens and/or saves changes for any tab of the Batch Execution
Configuration dialog box.

To configure any electronic signatures, you must select the Enable Batch Execution
Auditing check box in the Electronic Signature tab in the Batch Execution
Configuration dialog box.

For each command, select the Use Default Signature Requirements, or assign
specific signature requirements. After selecting the signature requirement for each
command, you specify the Windows security groups that you want to authenticate
against. You can select a security group by right-clicking the security group field and

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selecting the Browse option. The following figure shows an example of signature
configuration for the Batch Execution Configuration, Recipe Editor, and Equipment
Editor.

Electronic Signature tab in the Batch Execution Configuration Dialog Box in the
WorkSpace

When the Batch Execution captures an electronic signature, it records the signature
in the AUDITTABLE in the database. The AUDITTABLE table captures all design-

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time electronic signatures, including those in the Audit Reporter and the
WorkInstruction Editor. You can view the signatures in the AUDITTABLE using the
Batch Execution Audit Reporter application, or directly from your SQL or Oracle
database.

ActiveX Controls
In the Batch Execution ActiveX controls, you configure signature requirements from
the Electronic Signature property page. This property page is available at design-
time only. As shown in the following figure, this dialog box is similar to the Batch
Execution Configuration dialog box in the WorkSpace.

Sample of the Electronic Signature Property Page in the Batch Execution ActiveX
Controls

You can access the Electronic Signatures Property Page from the following ActiveX
controls:

• BatchList
• BatchAdd
• BatchOperatorPromptsList

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• BatchBindingPromptsList
• BatchManualPhase
• BatchSFC
• BatchActivePhaseList
• BatchCampaignClient

When the ActiveX control captures an electronic signature, the signature is recorded
in the BATCH_CMD_SIGNATURE_SUCCESS table, along with the computer
name and time stamp of the signature, as well as other data.

Audit Reporter
To configure electronic signatures in the Audit Reporter, from the Tools menu
choose Options, and then Electronic Signature. Select the Enable Authority Check
checkbox, as shown in the following figure.

Electronic Signature Dialog Box

When you enable authority checks in the Audit Reporter, Batch Execution requires a
user name and password from the iESigAdministrators Windows security group.
After you enable this option, you must enter a user name and password from the
AuditReporterUsers Windows security group whenever you start the Audit Report,
or extract document data from a saved recipe or area model.

When the Audit Reporter captures an electronic signature, the signature is recorded
in the AUDITTABLE in the database. You can view the captured signatures in the
AUDITTABLE using the Batch Execution Audit Reporter application, or directly

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from your SQL or Oracle database.

Understanding Audit Versioning

In addition to the electronic signature capability, Batch Execution implements
automatic versioning of the Recipe and Equipment Editor files. When you create an
area model or recipe in a Batch Execution Editor or Workspace, Batch Execution
assigns a globally unique identifier (GUID) to distinguish it from other versions of
the file.

When Batch Execution first assigns the GUID, it assigns an audit version number of
1. Each time you save the file with changes, the audit version automatically
increments by one. However, for recipe files which include sub-recipes, the audit
version number of the sub-recipe file does not increment unless there is a change in
the sub-recipe itself or in the area model.

When you save a file, Batch Execution streams the contents of the file out as an
XML document to the audit trail in the database. Batch Execution generates XML
schemas for both the Recipe and Equipment Editor files.

An example of the audit versioning information captured with a recipe is shown in

the following figure. Notice that the Recipe Editor captures the audit version number
of the area model against which the recipe was constructed.

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Audit Information Dialog Box in the Recipe Editor

Viewing the Audit Trail

You can view the design-time audit trail data for your Batch Execution system from
the Batch Execution Audit Reporter. This includes the commands developers

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performed, with the required electronic signatures, from the following Batch
Execution applications: the Recipe Editor, Equipment Editor, Batch Execution
Configuration in the WorkSpace, the WorkInstruction Editor, and the Audit
Reporter.

Through the Audit Reporter, you can quickly generate a report to examine the
change history of the versioned XML files (also called documents) saved from these
applications. After generating the report, plant personnel can generate, print, or
export reports to XML, HTML, or Microsoft® Excel® formats.

The following figure displays an example of a report run through the Audit Reporter.

Audit Reporter Application

To run a report, first select the data source from which you want to retrieve data.
Open the Report Template dialog box to review and select the displayed columns
and search criteria. Select Run from the Report menu, or click the Run button. Wait a
few seconds for data to populate in the Audit Reporter spreadsheet. The amount of
time that you wait, depends upon the size of the results returned by the query.

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 Appendix: Batch Execution Terminology

Appendix: Batch Execution

Terminology
Active Binding – Allows Batch Execution to bind and re-bind units to unit
procedures at multiple stages in a batch's life cycle including when a
batch is created or in production. Recipe authors can configure recipes to
automatically allocate equipment to batches based on (1) the properties of
the equipment entities and (2) the real-time conditions on the plant floor.

Active Journaling – The process of recording Batch event data in a relational

database.

ActiveX – A defined set of technologies developed by Microsoft. ActiveX is an

outgrowth of two other Microsoft technologies called OLE (Object
Linking and Embedding) and COM (Component Object Model). ActiveX
controls use ActiveX technologies. Batch Execution supplies a set of
ActiveX controls for use in any OLE container, such as web browsers,
Proficy iFIX WorkSpace, and Visual Basic.

And Structure – The logic for parallel processing. Use this sequence selection
when you need two or more steps to run in parallel.

Application Feature – Application functions protected by security. For

example, releasing a recipe to production is a distinct function with a
distinct security property.

Arbitration – The negotiation of equipment allocation when the equipment is

requested by more than one batch or operator.

Archiver – The component of Active Journaling that writes event data to the
relational database.

Area – A physical, geographical, or logical grouping of equipment. In Batch

Execution, an area contains process cells, units, and equipment phases.

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Area Model – A database that contains the definitions of the process cells,
units, and equipment phases that represent a physical, geographical, or
logical grouping of equipment used to build and execute recipes.
Typically, an area model contains all the equipment at a plant.

Array – A list of variables. You define parameter arrays for phases in the
process controller. Phase parameter arrays store phase parameter values.
A phase parameter array contains a number of elements, which are
referenced using an array index. Each element in a phase parameter array
can store one phase parameter value.

Batch – The material that is being produced or that has been produced by a
single execution of a batch process.

Batch ID – A name given by the operator to each batch, which is typically

unique. You cannot use the following characters in the batch ID: left
bracket { [ }, right bracket { ] }, left parenthesis { ( }, right parenthesis { (
}, comma { , }, double quotes { " }, single quotes { ` }, new line { \n },
carriage return { \r }, tab character { \t }, or NULL.

Batch Journal – An ASCII text file produced by the Batch Execution Server for
each batch added to the batch list and accessed by the Batch Execution
Client. These reports detail information such as status information about
the batch; recipe header information; changes in the state of recipe steps,
values, ownership, and mode; requests for changes of state, operator
information, and changes in mode; informational messages about phase
logic requests and responses; arbitration of resources; changes in batch
ownership and mode; and the production of a batch.

Batch Process – A sequence of one or more phases that must be performed in a

defined order and results in finite quantities of material.

Batch Report – A report generated at the conclusion of a batch that details

events that happened while the batch was running.

Batch Serial Number – The unique identification number assigned to each

batch by Batch Execution.

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Batch Server Manager – The Batch Execution application that is used to

manage and monitor the Batch Execution Server, including starting and
stopping the Batch Execution Server.

Class-Based Recipe – A recipe that defines equipment in terms of a unit class

and not specific unit instances. This feature allows the recipe to run on
any unit in the class.

COM (Component Object Model) – The Component Object Model (COM) is

the underlying architecture that forms the foundation for higher-level
software services, like those provided by OLE.

Common Resource – A resource that provides services to more than one

requester. In Batch Execution, they are control modules such as pumps,
motors, or valves that are shared between phases or units.

Control Module – Consists of sensors and other control modules that together
perform a specific task. Control modules perform regulatory or state
control over their constituent parts.

Control Recipe – Defines the manufacturing environment for a single batch and
includes the specific equipment and raw materials to be used. Control
recipes are devised from master recipes.

DCOM (Distributed Component Object Model) – A protocol that enables

software components to communicate directly over a network in a
reliable, secure, and efficient manner.

DDE Server – Server that retrieves data from any NetDDE-aware process
hardware. DDE (Dynamic Data Exchange) is a form of communication
that uses shared memory to exchange data between applications.

Deferred Parameter – Defines a value that is passed to another recipe. By

deferring a parameter, you instruct a recipe to retrieve the phase
parameter's value from a recipe parameter and not from the area model.

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Destination Unit – The unit where the equipment pathing connection ends. For
example, if a reactor feeds into a fermentor, the reactor is the origin unit
and the fermentor is the destination unit.

Device – A single, physical piece of plant equipment that has an active function
in the process. Examples: valves, pumps.

Dwell Time – The length of time a phase maintains a specific state. The dwell
time is used by the Soft Phase Server.

Enumeration – A list of strings that can be referenced by their ordinal offset in

a list. For example, Sunday=0, Monday=1, Tuesday=2.

Enumeration Set – A logical grouping of enumerations.

Equipment Database – See Area Model.

Equipment Editor – The Batch Execution application used to configure an area

model.

Equipment ID – A unique ID that is assigned to all equipment configured in the

Equipment Editor. This ID is used to acquire and release resources. It
must match the equipment ID used by the phase logic in the process
controller.

Equipment Module – Consists of equipment and control modules that together

perform a minor processing task (a phase). In Batch Execution, phases are
directly tied to the equipment modules on which they execute.

Equipment Capacity – The amount a unit can contain, transfer, or process.

During Active Binding, Batch Execution ensures that the units allocated
to unit procedures during batch production meet the minimum capacity
requirement defined for the unit procedure.

Equipment Pathing – Connections drawn in the area model that determine the
valid execution paths for a batch.

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Equipment Phase – A phase that is part of the equipment control. The logic for
an equipment phase resides in the process controller.

Equipment Phase Tags – The tags used to tie equipment phases to the
equipment. In Batch Execution, you tie equipment phases to the
equipment by specifying the equipment-specific addresses for ten
standard tags plus any parameter, report, and request tags required by the
phase. By specifying these tags, you are configuring a unit's equipment
phase. These tags are required by the Phase Logic Interface (PLI). The
PLI is programmed in the process controller and provides a standard
interface between the Batch Execution Server and the equipment phase.

Event/log File – During operation, each Batch Execution Server maintains a

historical record of the commands it received and the operations
performed. Batch Execution stores this record as an event. Each event is
identified by the batch serial number and the .EVT extension. These file
resides in the Batch Execution Journals directory.

Failure ID – The ordinal associated with a string in the PHASE_FAILURES

enumeration set.

Formula Parameter – See Recipe Parameters. The term Formal Parameter was
replaced with Recipe Parameter in version 4.5 of the product.

Hold Propagation – The hold propagation controls how the Batch Execution
Server responds when a phase fails. In general, when a phase fails, the
phase's hold logic executes and the PLC sends a hold command to the
Batch Execution Server. The Batch Execution Server can ignore the hold
command (no hold propagation) or can respond by holding: a phase, an
operation, a unit procedure, or the entire batch procedure.

Jacobson Links – Connections that are drawn within a recipe's sequential

function chart (SFC) to graphically represent a necessary physical
connection between unit procedures.

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Logical Data Model (LDM) – The table structures and rules that represent the
storage of Batch Execution recipes, events, and electronic signatures in a
relational database.

Loop – Defines the logic to repeat a series of steps multiple times.

Manifold Object – A control module that is used to connect multiple units as

part of the area model's equipment pathing.

Manual Mode – A state associated with a step in a batch. When a step is in

Manual mode, its transition does not execute until an operator sends a
message instructing it to do so.

Master Recipe – A recipe that defines the equipment requirements to

manufacture a product. This equipment is grouped into process cells.
Control engineers design master recipes to run on many different lines
within a process cell.

Maximum Owners – Identifies the maximum number of owners that can

simultaneously own an equipment resource. It is used to arbitrate
resources and typically is set to one to allow only one owner at a time.

O-Auto Mode – A state associated with a step in a batch. When a step is in O-

Auto mode, its transition executes and an operator can send commands to
its procedure.

OLE Object – A document, graphic, or other component from an application

that supports Object Linking and Embedding (OLE). For example, an
OLE object can be a Word document or Excel Spreadsheet. These OLE
objects are created in one application and can be embedded into another
application. In Batch Execution, OLE objects can be embedded into a
project where they can be opened and edited from the Proficy iFIX
WorkSpace.

OPC (OLE for Process Control) – Defines standard objects, methods, and
properties for meeting interoperability requirements of real-time process
automation applications.

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 Appendix: Batch Execution Terminology

OPC Item – A named data structure accessed through OPC using a request or
advise.

OPC Server – An application that makes its data available to other applications
using OPC. Batch Execution includes an OPC server for the iFIX process
database.

Operation – An independent production activity within a unit procedure,

consisting of phases and the algorithm necessary for the initiation,
organization and control of those phases. There may be one or more
phases within an operation that may execute sequentially or concurrently.

Operator Message – Identifies a string that is sent to the operator when the
phase executes. The message ID must correspond with the ID used by the
phase logic.

Operator Prompt – A phase parameter that prompts the operator for a value.

Or Structure – The logic for a decision you want a recipe to make. The result
of the decision determines the path that the recipe executes.

Ordinal – Number used by the phase logic to represent an enumeration.

Origin Unit – The unit where the equipment pathing connection originated. For
example, if a reactor feeds into a fermentor, the reactor is the origin unit
and the fermentor is the destination unit.

P-Auto Mode – A state associated with a step in a batch. When a step is in P-

Auto mode, its transition executes but an operator cannot send commands
to its procedure.

Parallel Production – When two or more steps must be complete before the
next step can execute.

Phase Link Group – A list of phases that communicate with each other.

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Phase Logic – Automates the equipment in a plant. Contains the instructions to

sequence the individual equipment connected to the physical devices. It is
the code that contains the control steps such as opening a valve, starting a
pump, or stopping a totalizer.

Phase Memory Variable – A named storage space that exists in the process
controller's memory to store the values for 15 unique data items that the
Batch Execution Server and the phase use to communicate.

Phase Message – Identifies a string that is sent to the operator when the phase
executes. The message ID must correspond with the ID used by the phase
logic.

Phase Parameter – Phase parameter are specified during the development of

the area model.

Phase Parameter Array – Resides in the process controller and contains a

number of elements that are referenced using an array index. Each
element of a phase parameter array can contain one phase parameter
value.

Phase Partners – The phases required for the selected phase to operate.
Typically used to synchronize phases.

Phase Report – Reports that detail actual process values or batch values used
by the equipment phase. This information is uploaded from the phase
logic in the process controller to the Batch Execution Server after the
phase completes.

PLI (Phase Logic Interface) – The interface between the Batch Execution
Server and the phase logic. The PLI is the Batch Execution-specific
portion of the phase and contains the state transition logic. It resides in
the controller.

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 Appendix: Batch Execution Terminology

Primary Journal – The primary journal is located in the path where the Batch
Execution Server first tries to write the event file. If the primary path is
unavailable, the Batch Execution Server writes the event file to the
secondary path.

Procedure – Defines a process strategy for making a batch. Procedures consist

of unit procedures defined for a recipe.

Process – A sequence of chemical, physical, or biological activities for the

conversion, transport, or storage of material or energy.

Process Cell – Consists of all the production and supporting equipment

necessary to make a batch. It may include one or more production lines.

Process Cell with Fixed Path – A process cell in a network environment for
which the path cannot be altered by an operator.

Process Cell with Variable Path – A process cell in a network environment for
which the path is chosen by an operator when the batch is scheduled for
production.

Process Stage – A part of a process that usually operates independently from

other process stages and that usually results in a planned sequence of
chemical or physical changes in the material being processed.

Production Report – A report generated at the conclusion of a batch that details

events that happened while the batch was running.

Project – The entire set of elements needed to deliver a batch solution. These
elements include the recipes, pictures, configuration files, and area model.

Proficy Batch Execution Archiver Manager – The Batch Execution

application that is used to start and stop the Batch Execution Archiver.

Proficy Batch Execution Client – The graphical Batch Execution application

used by the operator to monitor and control batches.

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Proficy Batch Execution Server – The Batch Execution application that

coordinates the function of your recipes, the area model, and each Batch
Execution Client during production.

Proficy Batch Execution Service Configuration Utility – The Batch

Execution utility that is used to configure the Batch Execution Server,
Archiver, and EIB Server to run as Windows services.

Proficy Batch Execution WorkSpace – The application used to create and

modify objects within a project.

Recipe – Defines the sequence of steps to produce a product.

Recipe Author – The individual responsible for creating a recipe.

Recipe Directory – The directory in which all recipe files are stored.

Recipe Editor – The Batch Execution application used to develop recipes.

Recipe Parameters – Variables used to control process values such as time,

temperature, and quantities. Recipe parameters let you create flexible and
reusable recipes.

Recipe Header – Administrative information about the recipe. This information

includes the procedure identifier, version number, version date, and
author.

Recipe Hierarchy – The S88.01 procedural model. This model defines

procedures, unit procedures, and operations in a hierarchy of recipes. The
Recipe Editor conforms to this model.

Recipe Management – The process of creating, maintaining and, if necessary,

deleting recipes.

Report Parameter – Variables, defined in the area model that represent process
values from the PLC.

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Request Tags – Functions that enable the phase logic to request the Batch
Execution Server to perform specific actions, such as acquiring and
releasing equipment and sending phase messages.

Resource – A single entity within the area model that is used in the production
of a batch.

Resource Class – A logical grouping of common resources.

Restart Control – Controls how the Batch Execution Server, EIB, or Soft Phase
Server starts. The restart mode can be:

Cold restart – Select Cold to always restart the server in cold restart mode. In
cold restart mode, the Batch Execution Server provides an empty batch
list.

Warm restart – Select Warm to always restart the server in warm restart mode.
In warm restart mode, the Batch Execution Server restores the batch list
and the state of the server to their last known state.

Prompt – Select Prompt (the default setting) to prompt users to select the restart
mode: Warm or Cold.

SCADA Server – An iFIX server that communicates with process hardware and
stores process values in a process database.

Scale Factor – A quantity that defines the percentage of a batch to be produced.

SCU (System Configuration Utility) – The SCU lets you configure the alarm
routing, the network connections, the tasks that startup automatically, the
SQL connections, and the SCADA and I/O driver settings.

SFC (Sequential Function Chart) – The graphical representation of a recipe.

Shared Resource – A resource shared between one or more process cells.

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Single Step Mode – When a phase is set to single step mode, the phase
transitions to the next programmed pause location and waits for the
operator to issue a Resume command. The pause locations are
preprogrammed into the phase logic. Typically, the phase logic is in
single step mode when testing a phase.

Soft Phase Server – The Batch Execution application that handles the execution
of soft phases.

Soft Phase – A PC-based phase that executes its phase logic via an executable
program running on a PC, or other non-controller device.

State – The condition of a piece of equipment or a procedural element at any

given time. Possible states are Aborted, Aborting, Complete, Held,
Holding, Idle, Ready, Restarting, Running, Stopping, and Stopped.

State Transition Logic – The logic within the PLI that provides a standard
interface to the project-specific phase logic. The state transition logic
receives commands from the Batch Execution Server or the operator and
then initiates the different components of the project-specific phase logic.
It resides in the controller.

Step Buffer – Used to store the previous value of the step index within the PLC.

Step Index – The current step of the active phase in the PLC.

Step Parameter – A parameter for a step defined in the recipe.

Tag – An individual I/O point in the PLC.

Tag Class – Defines common properties for a class of tags. Used to create class-
based recipes.

Topic – The subdivision identifier within the DDE Application from which to
retrieve information.

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Transition – Defines when a recipe moves from one step to another in the
sequential function chart.

UNC Paths – Microsoft's Universal Naming Convention (UNC) to access

project files that are stored on other machines within your network. The
syntax for UNC paths is as follows:

\\machinename\sharename\path\filename

Unit – A major piece of equipment in a process cell that performs a specific

task. It consists of all the equipment and control modules that are needed
to perform a task.

Unit Class – Defines common properties for a class of units. Used to create
class-based recipes.

Unit Instance – A specific unit in a unit class, defined by the information that
ties the equipment to the physical equipment.

Unit Priority – Indicates the priority of the unit, as compared to other units in
the same unit class. If multiple units are available for a batch, Batch
Execution selects the unit with the highest priority value. You can
configure a UNIT_PRIORITY tag to determine the priority value for a
unit or you can assign a static priority value to the unit in the area model
configuration.

Unit Procedure – One or more operations that control the function of a single
piece of equipment.

Unit Ready – Indicates whether the unit is ready for use. If the unit is not ready,
Batch Execution cannot allocate the unit to a batch. You can configure a
UNIT_READY tag to determine if the unit is ready, or you can configure
the unit as "always ready" or "always not ready" in the area model
configuration.

Unit Tags – Tags that are associated with a unit, such as temperature and level
tags. Unit tags are accessible to all phases that execute on that unit.

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Unit Tag Class – A variable name assigned to a class of unit tags. Used in
recipe transitions to implement class-based recipes.

VBEXEC.LOG – A list of errors that occurred during the production of a batch.

In addition to being written to the log file, severe errors and warnings are
sent to the SCADA node as alarms.

VBIS – A set of OLE Automation interfaces that allow 3rd party applications
(Visual Basic, C++) to manipulate information from the Batch Execution
Server, area model, and recipe database.

Watchdog – The name of an item in the DDE or OPC Server used by the Batch
Execution Server and the respective data server to ensure a live
communication connection between the two. The Batch Execution Server
periodically writes a 1 to the watchdog and checks that the data server
then writes a 0.

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Index
A architecture

acknowledging prompts ..................... 66 client-server...................................... 5

Active Binding typical Batch Execution ................... 6

configuring in recipes .................... 73 archiver

configuring in the area model ........ 72 configuring ..................................... 44

example.......................................... 74 overview ......................................... 44

in sample application ..................... 56 archiving data ..................................... 88

understanding................................. 71 area

Active Journaling in sample application ..................... 52

architecture .................................... 44 level ................................................ 17

components of................................ 44 area model

ActiveX controls configuring ..................................... 52

BatchList control ........................... 67 configuring Active Binding in ....... 72

overview ........................................ 11 configuring areas ............................ 52

using .............................................. 67 configuring equipment phases ........ 52

alarms, viewing .................................. 66 configuring process cells ................ 52

arbitrating resources .......................... 66 configuring unit classes .................. 52

113
 configuring unit instances .............. 52 performing supervisory control ...... 33

area model ......................................... 17 Batch Execution Soft Phase Server .... 60

automatic binding .............................. 73 batch journal

B viewing ........................................... 66

Batch Execution batch operations

benefits of using............................... 4 task overview ................................. 62

Client ............................................... 6 using iFIX ...................................... 62

integrating ERP.............................. 88 using the Batch Execution Client ... 62

Server ............................................... 6 batches

system components .......................... 6 adding to the Batch List ................. 31

Batch Execution Archiver archiving event data ....................... 88

understanding................................. 44 controlling ...................................... 66

Batch Execution Client controlling with ActiveX

controls ....................................... 67
not using ........................................ 87
controlling with VBIS .................... 69
operations tasks in ......................... 62
monitoring ...................................... 66
overview .......................................... 6
scheduling ...................................... 31
Batch Execution development
workstation ...................................... 6 states ............................................... 65

Batch Execution Server understanding execution................. 64

communicating with ...................... 51

114
 Index

C control modules

Campaign Manager............................ 87 as common resources ..................... 20

capacity .............................................. 72 described ........................................ 20

class-based design.............................. 80 control recipe

class-based recipes creating ........................................... 26

implementing ................................. 80 described ........................................ 26

in sample application ..................... 57 linking to the equipment................. 36

client-server architecture ..................... 5 control strategy

common resources designing ........................................ 38

defining control modules as ........... 20 equipment requirements ................. 41

control activity model identifying the process flow ........... 39

defined ........................................... 14 outlining the general procedure ...... 38

described ........................................ 25 partitioning equipment ................... 39

process control ............................... 34 controlling

process management ...................... 33 batches............................................ 66

production information phases ............................................. 66

management ............................... 34
custom applications
production planning &
scheduling .................................. 31 campaign manager ......................... 31

recipe management ........................ 26 executing batches ........................... 31

unit supervision.............................. 33

115
 legacy system connection determining availability ................. 31
manager ..................................... 87
linking to the control recipe ........... 36
using VBIS to develop ................... 87
partitioning ..................................... 39
D
requirements for production ........... 26
demo project ...................................... 14
equipment capacity
designing a control strategy ............... 38
in Active Binding ........................... 72
developing
equipment hierarchy ........................... 16
area model ..................................... 52
equipment module
parameters...................................... 56
described ........................................ 20
pictures .......................................... 61
equipment pathing
projects .......................................... 47
in Active Binding ........................... 72
recipes ............................................ 56
equipment phase class
development tasks
defined............................................ 20
overview ........................................ 47
sample configuration ...................... 20
E
equipment phase instance
Electronic documentation .................... 1
defined............................................ 20
embedding OLE documents .............. 48
sample configuration ...................... 20
equipment
equipment phases
allocating to batches ...................... 31
in sample application ..................... 52
definition guidelines ...................... 16
understanding ................................. 52

116
 Index

equipment status ................................ 72 iFIX

ERP system Clients .............................................. 6

integrating recipe data.................... 26 HMI .................................................. 8

integrating with .............................. 88 integrating Batch Execution with ..... 8

examples pictures ........................................... 61

Active Binding............................... 74 SCADA ............................................ 8

class-based design.......................... 80 SCADA Servers ............................... 6

equipment pathing ......................... 74 iFIX database

phase synchronization.................... 82 monitoring raw materials ............... 31

sending and receiving phase iFIX pictures

messages .................................... 82
operations tasks in .......................... 62
F
integrating
forced bindings .................................. 73
Batch Execution with ERP ............. 88
G
iFIX with Batch Execution............... 6
general procedure .............................. 38
J
general recipe..................................... 26
Jacobson Links
H
defined............................................ 76
header ................................................ 26
in Active Binding ........................... 73
I
L
IEC 1131-3 standard .......................... 12
legacy system connection manager .... 87

117
logical data model (LDM) parameters

storing recipes in ............................ 59 developing ...................................... 57

M in sample application ..................... 57

master recipes recipe .............................................. 26

creating .......................................... 26 phase logic

minor processing task ........................ 20 communicating with ....................... 51

monitoring batches ............................ 66 designing modular .......................... 52

O making requests from the Server.... 52

OLE documents ................................. 47 programming .................................. 50

OPC re-using .......................................... 23

overview of .................................... 13 understanding ................................. 52

operations phase partners

re-using .......................................... 26 synchronizing phases ..................... 81

operator prompt ................................. 73 phase reports

P reporting process values ................. 45

P&ID diagram ................................... 39 phase requests .................................... 81

parallel processing phases

constructing SFCs for .................... 59 controlling ...................................... 66

in sample application ..................... 59 states ............................................... 65

synchronizing ................................. 81

118
 Index

physical model stage ............................................... 35

defined ........................................... 14 process cell

objectives ....................................... 16 described ........................................ 18

piping and instrumentation diagram .. 39 in sample application ..................... 52

PLI multiple-path .................................. 18

programming ................................. 50 multi-product, network path ........... 18

state transitions .............................. 51 network-path .................................. 18

understanding................................. 51 single-path ...................................... 18

procedural control model process controller, programming ....... 50

defined ........................................... 14 process flow diagram ......................... 39

described ........................................ 23 process model

sample hierarchy ............................ 23 defined............................................ 14

procedure described ........................................ 35

described ........................................ 26 process............................................ 35

process process action ................................. 35

action ............................................. 35 process operation............................ 35

control ............................................ 34 process stage .................................. 35

described ........................................ 35 process parameters ............................. 26

management ................................... 33 production information

management ................................... 34
operation ........................................ 35

119
production planning & scheduling..... 31 R

production schedule ........................... 31 raw material, determining

availability...................................... 31
Proficy Batch Execution
WorkSpace recipes

developing projects ........................ 47 class-based ..................................... 26

overview .......................................... 9 components of ................................ 26

programming configuring Active Binding in ....... 73

phase logic ..................................... 50 control ............................................ 26

PLI ................................................. 50 developing ...................................... 56

projects equipment requirements ................. 26

area model ..................................... 47 general ............................................ 26

components of.................................. 9 header ............................................. 26

configuration files .......................... 47 in sample application ..................... 57

developing ..................................... 47 levels of .......................................... 26

folders ............................................ 47 managing ........................................ 26

OLE documents ............................. 47 master ............................................. 26

recipes ............................................ 47 parameters ...................................... 26

setting recipe storage type ............. 59 procedure........................................ 26

prompting operators ........................... 31 releasing for production ................. 26

prompts, acknowledging .................... 66 site .................................................. 26

120
 Index

storing in a relational database....... 26 defined............................................ 14

types ............................................... 26 equipment definition guidelines ..... 16

relational database models ............................................ 14

archiving data to ............................ 44 objectives ....................................... 14

managing information .................... 34 S88.01 models

storing recipes in ............................ 26 control activity ............................... 14

reports, developing custom ................ 45 physical .......................................... 14

requests, programming in phase procedural control .......................... 14

logic ............................................... 52
process............................................ 14
resources
recipe types .................................... 26
allocating to batches ...................... 31
S88.01 models .................................... 26
arbitrating ...................................... 66
sample application
determining availability ................. 31
equipment requirements ................. 41
re-using
general procedure ........................... 38
operations ...................................... 26
P&ID diagram ................................ 39
phase logic ..................................... 23
project items ................................... 47
unit procedures .............................. 26
understanding ................................. 37
S
scheduling batches ............................. 31
S88.01
servers
Batch Execution compliance ......... 12
Batch Execution ............................... 6

121
SFC unit classes

building recipes with ..................... 12 described ........................................ 19

constructing parallel processing..... 59 in sample application ..................... 52

SFC view screen ................................ 66 unit instances

site recipe ........................................... 26 described ........................................ 19

Soft Phase Server ............................... 60 in sample application ..................... 52

standards ............................................ 12 unit priority

state transition logic tag................................................... 72

in PLI ............................................. 51 unit procedure capacity ...................... 73

synchronized phases unit ready ........................................... 72

described ........................................ 81 units

T allocating to batches ....................... 33

testing your process ............................. 6 supervision of ................................. 33

U V

unit VBIS

definition guidelines ...................... 19 architecture overview of ................. 10

described ........................................ 19 campaign manager ......................... 69

sample configuration ..................... 19 controlling batches ......................... 69

sample equipment phase classes .... 20 determining raw material

availability.................................. 31

122
 Index

developing custom applications ..... 87 using to integrate data .................... 89

scheduling batches ......................... 31

123