SIMATIC BATCH - Siemens Industry, Inc.

SIMATIC BATCH
www.usa.siemens.com/batch
1
1

As part of the Siemens PCS 7 Totally Integrated Automation (TIA) vision for
batch customers, which promotes a shared production and business automation
solution, Siemens provides SIMATIC BATCH.
SIMATIC BATCH makes it easy for PCS 7 batch users to implement S88.01-based
batch solutions. This product provides PCS 7 batch users with the means to easily
develop master recipes, plan batches, monitor and control executing batches,
and collect batch data.
TIA means that Siemens has not only tested SIMATIC BATCH stand-alone to
confirm each of its designed functions, but has system-tested it to ensure tight
integration with the other PCS 7 TIA components.
2

SIMATIC BATCH benefits
• Reduces project implementation time
• Increases control system code re-usability
• Reduces implementation cost
• Reduces time needed to modify recipes
• Fully utilizes process capacity
• Reduces batch cycle times
• Reduces product variability
• Minimizes off-spec products
• Increases equipment utilization times
• Reduces product changeover times
• Increases operator time devoted to
identifying process improvements
SIMATIC BATCH features
Master recipe development
SIMATIC BATCH master recipes are configured graphically at the
PCS 7 Operating System (OS) level without modifications to the
automation system (AS) controller configuration.
By using SIMATIC BATCH, master recipe developments can be made
by those personnel that are not as familiar with configuring SFCs,
but those who have the product manufacturing domain knowledge,
such as process engineers. However, by not using SIMATIC BATCH,
your master recipe developments are limited to only the control
engineers that happen to be familiar with configuring sequences
in the controllers. This type of recipe configuration requires the
controller configuration to be modified each time a recipe is added
or changed.
Planned batches
Single batches, as well as batch campaigns, can be planned with
SIMATIC BATCH. Planned batches are made available to an operator
only after going through a release process, thus preventing an
operator from starting a batch that has not gone through the
complete planning process.
Batch status
Runtime interfaces are provided with SIMATIC BATCH which makes it
simple for the engineer, shift supervisor, and operator to determine
the current status of batches in the system, as well as where each
batch is in its execution.
The SIMATIC BATCH batch manager controls each batch from the
time it is released until its completion. This includes allocating
units at the right time, supervising the execution of phases, and
carrying-out any operator manual commands to the batch. Without
any additional user configuration, SIMATIC BATCH automatically
collects all batch-related data, such as batch/phase start/stopping
time, recipe phase parameters used, batch related alarms, and all
operator interventions into the batch. This information is stored in a
relational database.
3

SIMATIC BATCH master recipe development functions include the ability to:
• Graphically develop unit independent flat and hierarchy S88.01 based master recipes. Units can be dynamically assigned during batch
execution.
• Simplify the integration of automatic and manual phases into a recipe procedure.
• Copy and Paste sections of recipe procedures within a single master recipe procedure, and also between master recipe procedures.
• Hide selected phase parameters at runtime to prevent accidental operator changes.
• Simplify the implementation of product grades (separation of formulas and procedures). This feature allows multiple formulas to be
associated with a single procedure. Each combination is a master recipe.
• Create reusable recipe operations. Operation instances are updated when changes are made to the library recipe operation.
• Identify master recipe candidate units by name or by equipment attributes.
• Manually or automatically assign master recipe version numbers.
4

SIMATIC BATCH batch planning tools include the ability to:
• Plan individual batches as well as batch campaigns.
• Manually define the order in which batches are to run.
• Identify and graphically resolve potential unit allocation conflicts during batch planning stage.
Drag and Drop Resolution of Unit Allocation Conflict
Unit Allocation Conflict During Batch Planning
• Dynamically allocate units to a batch. Units can be allocated during recipe creation, when a batch is scheduled, or at runtime when a
unit is needed by the batch.
• Monitor the status of all batches using out-of-the-box batch summary displays.
Planning List
Planned/Not Released
Status List
Running
Released
Results List
Archived
Closed
Completed
5

SIMATIC BATCH runtime features include the ability to:
• Graphically monitor and control batch executions.
Start Hold Stop
Pause Resume
Abort
Breakpoint
• Display the procedure of multiple control recipes simultaneously.
• Identify the status of the batch server(s) in the architecture.
• Enter electronic comments on a batch, recipe object, and/or batch event; essentially an electronic operator log.
• Change out Units in runtime for recovery from a unit failure without having to abort the batch.
• Edit the recipe procedure of an active batch (access protected). An example of when this comes in handy is when a batch is producing
off-spec material and actions not defined in the control recipe need to be taken.
Normal Batch Execution
Edit Running Batch Insert a New Phase Return to Normal Batch Execution
6

• Create a new master recipe from a completed batch execution.
• Use electronic signatures to control/document the progress of a control recipe. The signoffs are automatically captured to the
historical database.
• Collect/Store batch-related continuous data in the batch database.
SIMATIC BATCH provides batch configuration management tools. They include the ability to:
• Export/Import individual or group of recipes.
• Backup and restore libraries, master recipes, formulas, and materials.
7

Available in various PCS 7 system
architectures
SIMATIC BATCH can be utilized in all PCS 7 automation system architectures from small to large. The batch application used in a small
system architecture can run in a large system architecture.
• An example of a small system architecture is one where PCS 7 OS, ES, and SIMATIC BATCH all reside on the same PC hardware and
exchange data with AS controllers through a system bus.
• An example of a medium system architecture is a client-server architecture where the PCS 7 OS, ES, and SIMATIC BATCH reside on
separate PCs. The OS server exchanges data with AS controllers on a system bus. The SIMATIC BATCH server, OS, and batch clients reside
on a separate terminal bus and exchange data with the OS server.
• An example of a large system architecture is a client-server architecture with redundant PCS 7 OS and SIMATIC BATCH servers. A
SIMATIC BATCH server may exchange data with up to 11 sets of OS Servers. Redundant SIMATIC BATCH servers, OS, and Batch clients
reside on a separate terminal bus and exchange data with the redundant OS servers. The ES is also on a separate PC.
8

Applies to all batch
processes
SIMATIC BATCH is most useful in batch processes where one or
more of the following situations exists:
• Master Recipes are added, deleted, and/or modified
frequently, as in the case of a pilot plant or a tolling facility.
SIMATIC BATCH has a very efficient and user-friendly graphical
recipe editor.
• The manufacturing process equipment is used to produce
several products (multiple recipes).
SIMATIC BATCH makes it easy to create and manage a large
number of different recipes.
• Units to be used for the production of a batch are allocated
dynamically.
SIMATIC BATCH allows for dynamic assignment of units, even
after the batch is already active.
• Units to be used for the production of a batch are allocated
based on some logical criteria.
This enables the recipe author to identify candidate units for a
master recipe based on the unit attributes. This feature makes it
easy to add candidate units into a master recipe without having
to modify the master recipe.
• Batch data collection is important. Out-of-the-box, SIMATIC
BATCH provides batch data collection capability with no
additional configuration work.
Standard crystal reports batch reports are provided with the
product.
• Recipes can be written and maintained without the help of
a control engineer.
With SIMATIC BATCH, a process engineer, who knows the
processing equipment and the process activities needed to
produce a product, is able to create master recipes without
having to make changes to the controller configuration.
• It is essential to quickly identify where a batch is in its
execution.
With SIMATIC BATCH, the recipe procedure can be displayed
graphically without additional configuration work.
9

Integrates easily into PCS 7 OS
To make it easier for a user to access the SIMATIC BATCH interfaces, unit symbol and unit faceplate objects are available for integration into
a PCS 7 OS screen. From these objects:
• The batch procedure running in the unit can be accessed.
• Active equipment phases (Sequenctial Function Charts) in the unit can be displayed.
• An equipment phase can be started and controlled manually outside the confines of a batch. If there are phase parameters, they can be
modified before manually starting the equipment phase.
The following table identifies the components that comprise the SIMATIC BATCH product suite. The modularity of the components enables
users to easily automate a portion of their process initially and later expand their automation solution when appropriate.
Licensing of the SIMATIC BATCH components is simple to understand. It is based on the number of units in the process and on the required
functionality. The base SIMATIC BATCH package supports 10 units. Power packs are used to increase the number of units..
SIMATIC BATCH V7.1 Packages
Basic Package
Process Object Packages (20, 40, 100, unlimited units)
Batch Control Center Package
Content
Everything needed to start automating a batch process: Batch Database,
Batch Visualization, Recipe Editor, Batch Data Collection, and Batch Report;
license for up to 10 batch units
Increases the number of batch units above the default 10 units provided in
the Basic Package
Additional batch visualization client. Number of packages needed = (number
of concurrent batch visualization clients - 1)
Recipe System Package Additional recipe development client. Number of packages needed =
(number of concurrent recipe editors - 1)
Batch Planning Package
Additional batch planning client. Number of packages needed = (number of
concurrent batch planning)
Hierarchical Recipe Package
Ability to create Master recipe procedures that follow the full S88.01 recipe
procedure hierarchy
Recipe Operation Library Package
Ability to create recipe operation templates that are reusable in multiple
master recipes
Separation Procedures/Formulas Package
Ability to associate multiple formulas to a common recipe procedure
API Package
Provides third-party applications with access to SIMATIC BATCH data and
function
10

Siemens Industry, Inc.
333 Old Milton Parkway
Alpharetta, GA 30005
1-800-964-4114
info.us@siemens.com
www.usa.siemens.com/batch
Subject to change without prior notice
Order No. PABR-00069-0410
All rights reserved
printed in USA
©2010 Siemens Industry, Inc.
The information provided in this brochure contains merely
general descriptions or characteristics of performance
which in case of actual use do not always apply as described
or which may change as a result of further development
of the products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the
terms of contract.
All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use by
third parties for their own purposes could violate the rights
of the owners.