Transcript The Secret Life of S88 - OEE

The Secret Life of S88
(S88 as Seen by Users)
Jim Parshall
Eli Lilly and Company
Contents
Interpreting
S88
S88 Business
Challenges
The Future
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Needs for Interpreting S88
 Standards serve countless companies in many
different industries
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Must be written to cover the broadest ground
Nature of standards prevents lengthy examples or
interpretation details
 S88.01 is not a compliance standard
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It makes suggestions or provides examples
It does not list requirements
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
3
Reasons to Form SP88
 No universal model existed for batch control
 Users had a very difficult time communicating
their batch processing requirements
 Engineers found it very hard to integrate
solutions from different vendors
 Engineers and users had a difficult time
configuring batch control solutions
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Spirit of S88
 S88 isn’t just a standard for software,
equipment, or procedures
 It’s a way of thinking, a design philosophy
 Understanding S88 will help you better design
your processes and manufacture your products
S88 works with all
levels of automation
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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How Does S88 Help?
1. Modularity allows for easier global replication
and better return on investment
2. Isolates equipment from recipes
3. Design concepts make validation easier
4. S88-aware solutions help track product and
process data
5. Gathering requirements from customers and
conveying requirements to vendors is easier
6. Provides guidelines on how to recover from
abnormal events
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Improved Batch Process Metrics
Throughput
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Cost
Reduced batch cycle
time
Increased production
rate
Faster changeover time
More scheduled recipes
Reduced downtime
Faster process
development time
Faster new product
launches
The Secret Life of S88
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Reduced raw material
loss
Improved batch
consistency
Better equipment
utilization
Less time to add or
modify recipes
Lower engineering cost
Lower data capture cost
Better data availability
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Successful Batch Control Defines
These Elements
 Instructions on how to make a product
(recipes)
 The physical tools needed to make a product
(equipment entities)
 Methods to link recipes to equipment entities
(control activities)
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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A Recipe
Phases are the workhorses.
Other levels simply group,
organize, and direct phases.
Procedure
Make
Toothpaste
Unit
Procedures
Make Paste
Make Gel
Swirl
Operations
Prepare
Tank
Add
Ingredients
React
Add Water
Add Fillers
Phases
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
Add NaF
April 18, 2000
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An Example Process Cell
Process
Cell
Material Selection
Material
Charging
FT
Mix
Pressure
Control
M
Unit
Temperature
Control
TT
PT
Discharge
and
Recirc
Equipment
Module
Pump
FT
Control
Module
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
10
Interpretation of a Unit
Process
Cell
Unit
Equipment
Module
Control
Module
 Batching cannot occur without units; batching
occurs in units
 A unit runs a recipe to
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Combine ingredients
Perform a reaction
Add value to your product or interim product
 Don’t narrow your definition of a unit to just a
vessel
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In-line mixer
Pasteurizer
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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What is a Unit?
A Unit
Mix making batch tank
Pasteurizer
Reactor
Pump
Ingredient storage tank
Washing machine
Kitchen blender
Refrigerator
Dishwasher
The Secret Life of S88
Not a
Unit
4
4
4
4
4
4
4
4
4
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April 18, 2000
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What is the Scope of a Unit?
 Applying the S88 concept is much easier when
equipment dedicated to a single unit is
considered part of the unit
 If a dedicated unit resource is not
permanently associated with the unit, a lot of
unneeded overhead is involved to use it
Material Selection
Material
Charging
FT
Mix
Pressure
Control
M
Temperature
Control
TT
PT
Discharge
and
Recirc
Pump
FT
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
13
Equipment and Control Modules
Process
Cell
Unit
Equipment
Module
 Equipment modules group devices for performing
Control
Module
one or more specific processing activities
 Control modules “connect” software to the process
through actuators and sensors with all elements
treated as a single entity
 Equipment modules run portions of a recipe;
control modules do not
FT
Material Selection Material Charging
Equipment Module
Control Module
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Physical Model is Collapsible
Process
Cell
 A control module does not have to
Unit
Equipment
Module
be part of an equipment module to
be part of a unit
 A unit can “own” control modules
directly
 A process cell must contain at least
one unit
Control
Module
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Contents
Interpreting
S88
S88 Business
Challenges
The Future
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
16
Packaged Systems
 In bulk chemical operations, equipment
entities (tanks, valves, pumps, etc.) are
combined and integrated with control systems
 S88 works well when end-user assembles
stainless steel and integrates to form a
working system
 The application of S88 has been much more
focused on these type of operations
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
17
Packaged Systems
 Fill/finish-type operations found in the
consumer products industries can benefit
greatly from S88
 Equipment from these operations are typically
purchased from various OEMs
 Integration into a common S88 framework is
difficult
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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What Do We Do?
 Spec out equipment phases and have
integrator or “system OEM” link equipment
entities via recipes?
 A two-tier S88-aware architecture
 How about using S88.02 functions?
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S88 software links recipes to equipment control at a
level other than phase
S88 solution providers educate, assist, and influence
OEMs to follow an S88 methodology
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Contract Manufacturing
 Interpretation of supply chain is changing
 Contract manufacturing organizations (CMO)
are growing and evolving
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Used in food industry for years
Concept fairly new in pharmaceuticals
 Product “owners” may evolve into R&D and
marketing organizations
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Manufacturing will evolve to third-parties
Sales already partly transforming to third-parties
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Contract Manufacturing
 Product “owners” will deal with general and
site recipes
 Product manufacturers will deal with master
and control recipes
 Properly transforming a general recipe into a
master recipe will become even more critical
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Contents
Interpreting
S88
S88 Business
Challenges
The Future
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
22
S88 Beyond Manufacturing
 Theme park rides/attractions/shows
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Instead of making a product according to some recipe,
people are being entertained according to some
sequence
Anyone visited Alien Encounter at Disney’s Magic
Kingdom?
 Power generation
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Thinking of power in batches does not seem to make
sense, but state-based procedural control could be an
asset to a power plant
 Moving baggage at an airport
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
23
Final Thoughts
 S88 being a standard with international
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influence is a big selling point
Make sure your vendors are aware of S88
Don’t underestimate the benefits of making
your operator’s lives better
Make the process better
Don’t trash the old system just yet
You may always have to sell S88 - even after
projects are complete
An S88 solution is one element in a total
system of manufacturing
The Secret Life of S88
World Batch Forum 2000 / Atlantic City
April 18, 2000
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Thank You