Flexible automation of batch processes
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PUBLICIS
Subject to change without prior notice 10/04 | Order No. E20001-A190-P280-V1-7600 | DISPO 46303 | 41C8763 MK.AS.PS.XXXX.52.5.01 WS 10043. | Printed in Germany | © Siemens AG 2004
 Flyer Siamtic Batch_GB 05.10.2004 11:10 Uhr Seite 2
In the process industry, batch processes are assuming
increasing significance. Shorter product life cycles and the
productivity demanded by consumers are two reasons for
this change in importance. Other demands include the need
for consistent quality product, faster responses to market
conditions, production reproducibility (FDA compliance),
and compliance with legal standards and controls.
To satisfy these needs, new batch plants are more and more being
designed as multi-purpose facilities. This enables multiple products
to be produced using the same equipment set thus reducing
equipment idle time. In some cases, this flexibility also enables a
single product to be produced using different paths through the
equipment set that can result in increased product production and
reduced batch cycles.
The PCS 7 process control system offers an excellent solution for
the economical and effective implementation of batch processes
in a batch automation environment: SIMATIC BATCH.
SIMATIC BATCH can be used to implement a practical and highly
flexible batch solution. This product can be applied to all batch
processes. It can be used with batch processes that have single
path structures as well as to those processes that have network
structures. It can be used with facilities that produce one product
as well as facilities that product multiple products. It is a scalable
modular software package that can be used in both small pilot
facilities as well as in large production plants.
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Integration of SIMATIC BATCH SIMATIC BATCH can be linked to the higher-order IT
SIMATIC BATCH is fully integrated in SIMATIC PCS 7 level (MES/ERP) software packages. One way to do
and shares the same visualization and engineering this is through the use of the standard SIMATIC IT
tools as the other standard SIMATIC PCS 7 compo- interface. A second method is through an available
nents. The total integration of SIMATIC BATCH in the open API interface that enables you to develop your
plant s visualization system provides the operator own custom interfaces to third-party software
with the tools to easily monitor and control batches, packages.
and to quickly response to process exceptions.
Optimum adaptation to plant requirements
Integration makes it easy to consolidate batch data
SIMATIC PCS 7/SIMATIC BATCH enables you to im-
and batch-related continuous data, such as a unit s
plement a solution architecture that best reflects
temperature profile during the time the unit is
the needs of your solution. For small batch processes,
allocated to the batch, into a single comprehensive
an all-in-one node solution can be implemented.
XML based batch report that can be viewed using
For larger batch processes, a client-server architec-
a web browser, and/or printed.
ture can be used. To ensure high process availability
and complete batch data collection, redundant batch
Integration of SIMATIC BATCH in the SIMATIC PCS 7
servers can be implemented in the architecture.
engineering system means that engineering data
need to be entered only once. Once entered, the
Process-oriented recipe creation
engineering data is available for use by all SIMATIC
SIMATIC BATCH enables you to develop a batch
PCS 7 components. This reduces the time it takes
solution that follows the equipment and recipe
to engineer an application and minimizes data entry
hierarchies defined in ISA S88.01. In this model:
errors.
 Recipe procedures execute in a Process Cell
 Unit procedures, operations, and phases execute
in a Unit.
Integration of SIMATIC BATCH in the engineering system
Equipment-independent recipes and recipe used in the application. Additionally, the link
between a library ROP and an instance of the library
building blocks
ROP can be detached to allow for instance-specific
With SIMATIC BATCH, a master recipe is a sequence
modifications independent of the library ROP. ROPs
of process actions that describe how a batch product
can help reduce engineering and validation over-
is produced. These master recipes can be imple-
head.
mented as equipment-independent sequences. At
der IT
run time, the batch manager dynamically assigns
Validation
o do
a unit to the recipe. Using this capability, a single
Increasingly, today s plants require validation for
C IT master recipe can be used with different equipment
compliance with quality standards as well as for
units thus reducing the time needed to engineer a
lable
adherence to marketing and statutory requirements.
master recipe. The basic master recipe building block
your Traceable and reproducible production is particularly
is a recipe phase. The normal and exception handling
e important in a multi-product or multi-stream envi-
logic for a recipe phase is stored in an equipment
ronment. SIMATIC BATCH provides features that help
phase. PCS 7 enables you to create equipment phase
you follow GMP and FDA 21CFR Part 11 standards.
templates that are instantiated and assigned to as
nts At runtime, an Audit Trail feature automatically logs
many units as needed. Equipment phase templates
each step in a batch execution. All run time control
im-
make it easy to clone and validate equipment phases.
recipe activities and operator actions are captured
cts
Any change to an equipment phase template auto-
and stored to batch history. This information can
esses,
matically updates each instance that was created in
be printed out and/or displayed when required.
ed.
the project.
SIMATIC BATCH provides user access protection with
hitec-
Windows 2000-based centralized user management
Dynamic Unit Allocation
bility
SIMATIC BATCH supports true dynamic unit alloca- features. In the system, each user has a unique user
batch
ID and password that is assigned by the system
tion. This enables the assignments of units to a
re.
administrator. The user can be forced to change his
batch to be deferred until the units are actually
password the first time he logs in. A user s user ID
required by the batch. A number of unit allocation
defines the application and applicationfunctions
strategies are provided with the product. The unit
h
that the user is permitted to access. Electronic
allocation strategy can be selected based on the
e
signatures are available to support paperless
situation in the plant. This ensures flexible and
el:
production. An operator action can be defined to
optimum utilization of plant capacity.
require one or more sign-offs before the action is
Recipe Operation Procedures Library (ROP)
performed. You can also define sign-off requirements
ecute
A Library ROP is a structure of recipe phases built
control recipe phase status changes. The action
based on the unit classes defined in an application.
along with the signatures are captured to batch
A Library ROP can be used in multiple recipe unit-
history and can be viewed as part of the standard
procedures. Changes made to a Library ROP auto-
batch report for the batch.
matically updates each instance of this Library ROP
Allocation of subsystems at runtime
 Flyer Siamtic Batch_GB 05.10.2004 11:10 Uhr Seite 1
SIMATIC BATCH enables easy, flexible, user-friendly auto- Complete batch data management
mation of all batch processes and provides the tools that The production sequences are automatically documented
support you in complying with all applicable standards. in the batch log (on paper or electronically). Production
sequences are easily reproducible.
For you, SIMATIC BATCH means
Reduced validation cost
More production flexibility  a shorter time to
Runtime recipe modifications are automatically document-
market
ed. SIMATIC BATCH provides features like recipe version-
Production sequences are described in master recipes,
ing, user access control, runtime production audit trails
which can be generated or modified whenever necessary
and electronic signature (21 CFR Part 11).
by operating personnel that have the proper access
permission.
Reduction in operating costs and life cycle costs
All standard products from Siemens receive worldwide
Improved plant capacity utilization
Siemens service and support. You can purchase and install
SIMATIC BATCH supports dynamic unit allocation. The
Siemens products anywhere in the world and expect the
allocation of units (equipment) can be planned in advance
same top quality service and support.
and can be changed on the fly to reflect the latest
production requirements until the unit allocation actually
takes place.
SIMATIC BATCH  Highlights
Modular architecture with flexible hardware and Hierarchical recipes to ISA S88.01
software scalability  Process-oriented recipe generation
 Optimum adaptation to plant size and individual requirements  Simple, fast, fault-minimized recipe generation
 Grows with the plant, no expensive reserve capacities
Storing, archiving and comprehensive logging of batch
necessary
data based on state-of-the-art XML format
Redundant batch servers  Production becomes transparent and traceable
 High process availability
Reduced engineering and validation effort
 No loss of batch data
 SFC type/instance concept
 Automatic synchronization of batch data
 Separation of procedure and formula
Tight integration of SIMATIC BATCH in the HMI strategy
Unit-class-based ROP library development
and the PCS 7 engineering system
 Reusable
 No customer-specific interfaces required
 Centralized configuration
 One time entry of process model and engineering data
 Integrated alarm and message concept
Validation support
 Reliable operator guidance and safe, reliable response to
 Audit trail (modification log)
process faults
 Versioning for recipes, recipe operations and formulas
 Centralized user access management and electronic signature
Equipment-independent recipes
 Considerable simplification of recipe management and
validation
 Flexible recipe usage and optimum plant capacity
utilization
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The latest information on SIMATIC PCS 7:
www.siemens.com/simatic-pcs7
ented
ction
Web support:
www.siemens.com/automation/service&support
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The information provided in this brochure contains merely general
descriptions or characteristics of performance which in actual
Siemens AG
case of use do not always apply as described or which may
Automation and Drives
change as a result of further development of the products. An
obligation to provide the respective characteristics shall only
Industrial Automation Systems
exist if expressly agreed in the terms of contract.
P.O. Box 48 48
SIMATIC® is a registered trademark of Siemens. Other designations
D-90327 Nürnberg
used in this publication may be trademarks whose use by third
parties for their own purposes could violate the rights of the
owners.
www. si emens. com/ pr ocessaut omat i on
PUBLICIS
Subject to change without prior notice 10/04 | Order No. E20001-A190-P280-V1-7600 | DISPO 46303 | 41C8763 MK.AS.PS.XXXX.52.5.01 WS 10043. | Printed in Germany | © Siemens AG 2004