Design Patterns for Flexible Manufacturing

221 Pages·2007·9.647 MB·English

by  Brandl, Dennis

Brandl_finalpages.book Page III Tuesday, October 31, 2006 3:54 PM
DESIGN PATTERNS
FOR FLEXIBLE MANUFACTURING
by
Dennis Brandl
Brandl_finalpages.book Page IV Tuesday, October 31, 2006 3:54 PM
Copyright © 2007 by ISA—Instrumentation, Systems, and Automation Society
67 Alexander Drive
P.O. Box 12277
Research Triangle Park, NC 27709
All rights reserved.
Printed in the United States of America.
10 9 8 7 6 5 4 3 2
ISBN-13: 978-1-55617-998-3
ISBN-10: 1-55617-998-7
No part of this work may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise,
without the prior written permission of the publisher.
Notice
The information presented in this publication is for the general education of the reader.
Because neither the author nor the publisher has any control over the use of the
information by the reader, both the author and the publisher disclaim any and all liability
of any kind arising out of such use. The reader is expected to exercise sound professional
judgment in using any of the information presented in a particular application.
Additionally, neither the author nor the publisher have investigated or considered the
affect of any patents on the ability of the reader to use any of the information in a
particular application. The reader is responsible for reviewing any possible patents that
may effect any particular use of the information presented.
Any references to commercial products in the work are cited as examples only. Neither the
author nor the publisher endorses any referenced commercial product. Any trademarks or
tradenames referenced belong to the respective owner of the mark or name. Neither the
author nor the publisher makes any representation regarding the availability of any
referenced commercial product at any time. The manufacturer’s instructions on use of any
commercial product must be followed at all times, even if in conflict with the information in
this publication.
Library of Congress Cataloging-in-Publication Data in process
Brandl, Dennis.
Design patterns for flexible manufacturing / by Dennis Brandl.
p. cm.
ISBN 978-1-55617-998-3 (pbk.)
1. Flexible manufacturing systems. 2. Production
control—Standards—United States. I. Title.
TS155.65.B73 2006
658.5'1—dc22
2006035821
Brandl_finalpages.book Page V Tuesday, October 31, 2006 3:54 PM
To Diane for all of her support and understanding.
Brandl_finalpages.book Page XIII Tuesday, October 31, 2006 3:54 PM
L F
I S T O F I G U R E S
3–1 The recipe/equipment separation process...............................................18
3–2 The three types of control in S88 Design Patterns..................................19
3–3 Implementations of control types...........................................................20
3–4 Elements of a recipe.................................................................................23
3–5 A hierarchy of recipe types.......................................................................23
3–6 Recipe/equipment separation of functions..............................................26
3–7 Recipe/equipment information exchange...............................................27
3–8 ISA 95 equipment hierarchy....................................................................28
3–9 Equipment hierarchy as seen by a recipe.................................................32
3–10 The process cell........................................................................................32
3–11 Typical area-level production routing.....................................................33
3–12 A process-cell hierarchy...........................................................................34
3–13 Recipe to equipment linkage...................................................................36
3–14 Multiple recipes using the same equipment............................................37
3–15 Equipment phases and equipment tags...................................................38
3–16 Three trains within a process cell.............................................................40
4–1 Master and control recipes.......................................................................42
4–2 Recipe elements and procedural hierarchy..............................................43
4–3 Unit procedure, operation, and recipe phase example............................45
4–4 Expanded recipe procedure examples......................................................47
4–5 Different ways to collapse the recipe procedure......................................47
4–6 Procedure function chart elements..........................................................49
4–7 Explicit transaction..................................................................................49
4–8 Recipe operation with a loop...................................................................50
4–9 Multiple recipes requiring the same units...............................................51
4–10 Example of allocation and deallocation use............................................51
4–11 Example of transfer synchronization.......................................................53
4–12 Configuring a control recipe for a batch.................................................54
4–13 All product-related procedures in the recipe...........................................55
4–14 Operations in the equipment..................................................................55
4–15 The unfortunate reality of laying S88 onto an existing system...................56
4–16 Sample procedural control state model...................................................57
XIII
Brandl_finalpages.book Page XIV Tuesday, October 31, 2006 3:54 PM
XIV LIST OF FIGURES
4–17 Propagation of a recipe hold....................................................................58
4–17 Propagation of a recipe hold....................................................................60
4–19 Propagation of an equipment-initiated stop............................................61
4–20 Stop sequence............................................................................................61
4–21 Procedural element modes.......................................................................62
4–22 Semiautomatic operator control..............................................................63
4–23 Procedural element states and modes......................................................64
5–1 Types of control in automated systems...................................................68
5–2 Some interactions of types of control......................................................70
5–3 Automated control design pattern...........................................................70
5–4 Objects for automated control.................................................................71
5–5 Process cell structure.................................................................................73
5–6 Design pattern elements of a unit............................................................79
5–7 A three-unit process cell...........................................................................80
5–8 Unit boundaries........................................................................................82
5–9 Shared equipment modules and control modules...................................83
5–10 One-to-one unit to equipment module phase mapping.........................84
5–11 Equipment modules with multiple phases..............................................84
5–12 General-purpose charge phase.................................................................85
5–13 Unit recipe procedural control.................................................................88
5–14 Unit class example....................................................................................90
5–15 Equipment module structure...................................................................93
5–16 Typical equipment modules.....................................................................94
5–17 Sample equipment module hierarchy......................................................94
5–18 Sample equipment phase state and mode model....................................95
5–19 Equipment module pattern......................................................................96
5–20 Sample equipment state...........................................................................97
5–21 Complex equipment module states.........................................................97
5–22 Equipment module procedure control functions....................................98
5–23 Equipment module with multiple phases................................................99
5–24 SFC procedure diagram...........................................................................100
5–25 Equipment module EM53-E...................................................................103
5–26 Calculations performed in a shared equipment module.......................103
5–27 Sequence diagram for communication phases......................................105
5–28 Environmental phases crossing operation boundaries..........................105
5–29 Environment control using persistent actions.......................................106
5–30 Control modules within Unit U53.........................................................110
5–31 All low-level control modules within a process cell..............................111
5–32 Sample control module state models.....................................................111
5–33 Sample states for a valve.........................................................................113
Brandl_finalpages.book Page XV Tuesday, October 31, 2006 3:54 PM
LIST OF FIGURES XV
5–34 Control modules, the lowest-level of the equipment hierarchy................113
5–35 Sample valve control module representation........................................113
5–36 The equipment and control module pattern.........................................118
5–37 Simple material transfer paths...............................................................119
5–38 Transfer phases in units.........................................................................121
5–39 Single-use and multiple-use header transfers........................................121
5–40 Sample complex switching equipment module....................................123
5–41 Control hierarchy and equipment hierarchy........................................127
6–1 Recipe and equipment phases................................................................131
6–2 Manual execution of equipment phases................................................131
6–3 Objects in manual operations................................................................133
6–4 Mapping SOPs to units...........................................................................134
6–5 MPP instructions....................................................................................136
6–6 Basic pattern for manual interactions....................................................139
6–7 Control action automation....................................................................141
6–8 A unit with manual and automated phases...........................................143
7–1 Electronic board assembly......................................................................146
7–2 Nonstop continuous production...........................................................148
7–3 Production runs in continuous production...........................................148
7–4 NS88 rules...............................................................................................150
7–5 The NS88 Design Pattern.......................................................................151
7–6 End-of-batch detection and propagation...............................................153
7–7 Example phase state model....................................................................154
7–8 General-purpose NS88 equipment state model.....................................156
7–9 NS88 pattern for a filling unit................................................................159
7–10 Sample nonstop work center.................................................................159
7–11 Sample recipe for a nonstop process cell...............................................160
7–12 Time T1 with one batch running...........................................................160
7–13 Time T2 with new batch approaching...................................................161
7–14 Time T3 product switchover in FILL #1.................................................162
7–15 Time T4 product switchover in COAT #1..............................................163
7–16 Time T5 product switchover complete..................................................163
7–17 Using reporting units to report on a batch............................................165
7–18 Early detection of EOB...........................................................................167
7–19 Sequence diagram for EOB detection and calculation..........................167
7–20 Using a cleaning recipe between products............................................168
7–21 Sample startup recipe.............................................................................169
7–22 Example of a buffering unit...................................................................171
7–23 Buffering in a discrete process................................................................171
7–24 HOLD sequence diagram for units with buffers....................................172
Brandl_finalpages.book Page XVI Tuesday, October 31, 2006 3:54 PM
XVI LIST OF FIGURES
7–25 Switching path using a multi-use unit...................................................173
7–26 Switching path using a NS88 equipment module.................................173
7–27 NS88 switching path pattern..................................................................173
7–28 One-to-four switching path conveyor system.......................................176
7–29 Sequence diagram for the one-to-four switch........................................176
7–30 Many-to-many switching conveyor system...........................................178
7–31 A four-batch example.............................................................................178
7–32 Unit diagram with NS88 switching units...............................................179
8–1 A sample of a continuous process..........................................................185
8–2 Sample parameter changes for a switchover..........................................185
8–3 NS88 pattern for nonstop continuous production................................186
8–4 Units within a production unit..............................................................186
8–5 Typical NS88 continuous recipe.............................................................187
8–6 A typical NS88 product switchover recipe.............................................188
8–7 Recipes before product switchover.........................................................189
8–8 Switching products.................................................................................189
8–9 Units F1 and C1 switched......................................................................189
8–10 Switching to the new batch...................................................................191
9–1 Typical batch-merging situation............................................................194
9–2 Typical batch-splitting situation............................................................194
9–3 Pattern for merging and splitting batches.............................................196
9–4 Scope of upstream and downstream batches.........................................198
Brandl_finalpages.book Page XVII Tuesday, October 31, 2006 3:54 PM
L T
I S T O F A B L E S
3–1 Equipment Hierarchy Equivalent Levels..................................................31
4–1 Recipe Procedural Element States............................................................59
4–2 Recipe Procedural Element Commands...................................................62
4–3 Sample Procedural Control Modes..........................................................63
5–1 Design Pattern Rules for S88 Process Cells...............................................77
5–2 Design Pattern Rules for S88 Units..........................................................91
5–3 SFC Action Qualifiers.............................................................................101
5–4 Design Pattern Rules for S88 Equipment Modules................................108
5–5 Examples of Control Module Classes.....................................................117
5–6 Design Pattern Rules for S88 Control Modules......................................118
7–1 Sample Equipment Phase States.............................................................155
7–2 General-Purpose NS88 Equipment State Definitions.............................157
7–3 General-Purpose NS88 Equipment Mode Definitions...........................158
XVII
Brandl_finalpages.book Page XXIII Tuesday, October 31, 2006 3:54 PM
A
C K N O W L E D G M E N T S
I would like to thank all of the ISA SP88 Batch Control committee
members, both past and present, for their dedication and hard work in
developing the ISA 88 standard. Their hard work is what made this book
possible. I would also like to especially acknowledge Lynn Craig, David
Chappel, Velumani Pillai, Dave Emerson, Paul Nowicki, Keith Unger, Kate
Waters, Jean Vieille, Larry Faulkenau, Leo Charpentier, Michael Saucier, and
Bruce Becwar for their feedback and expertise as I developed the S88 and
NS88 design patterns.
XXIII
Brandl_finalpages.book Page XXV Tuesday, October 31, 2006 3:54 PM
A A
B O U T T H E U T H O R
Dennis Brandl is the founder and chief consultant for BR&L Consulting,
specializing in Manufacturing IT applications. He has been involved in
automation system design and implementation in a wide range of appli-
cations over the past 30 years. They have included biotech, pharmaceu-
tical, chemical plants and oil refineries, food manufacturing, consumer
packaged goods, Space Shuttle test systems, PLC-based systems, and batch
control systems.
Brandl is a U.S. expert on batch control to IEC, is currently chairman
of the ISA SP88 committee, and has been an editor and contributor to the
ISA SP88 Batch System control standards. He is also an active member of
ISA’s SP95 Enterprise/Control System Integration committee and is editor
of the set of standards. Brandl has a BS in Physics and an MS in Measure-
ment and Control from Carnegie-Mellon University, and a MS in
Computer Science from California State University.
XXV