System 800xA - The Power of Integration

System 800xA Batch Management

Overview
Batch management

800xA Batch Management supports dynamic recipe parameters.

Master recipe procedures can be configured with one or more
formulation parameters established as an expression, rather than
a constant value. This enables the control recipe to evaluate one
or more variable process conditions and dynamically update the
formulation parameter at run-time. Improved product quality and
reduced processing time are just two of the potential benefits when
using dynamic parameters in control recipes.

Often, operator or supervisor intervention in a batch

process means aborting the batch recipe procedure and
manually completing the batch. 800xA Batch Management
provides the tools to allow user intervention to make the
necessary adjustments and continue the processing of the
batch through the control recipe procedure. An operator
or supervisor can easily re-route the batch path to another
Integrated batch management
allowable unit if the originally selected unit is not available or
out-of-service. The most powerful feature, however, is the
System 800xA Batch Management is a powerful extensive runtime editing capability. Users with the correct
application software package for configuring, scheduling, permission level can perform a runtime edit on any currently
and managing batch operations improving batch executing recipe procedure. The runtime edit feature enables
production profitability, consistency, and traceability. the modification of any subsequent operation or phase in the
currently executing control recipe without stopping the recipe.
Increased productivity tools provide the agility, speed, and the Of course, all user-initiated changes are captured in System
control needed to respond to increasing production demands by 800xA audit trail and batch production record.
modeling, executing, and tracking information associated with
material and control flow across the plant. All process automation systems support interlocking
strategies at the control module level. Certainly, interlocks
800xA Batch Management is aligned with industry standards required for safety and preservation of process equipment
such as ISA88, ISA95, IEC 61512, and IEC 62264. It is further should reside at the controller level. However, in a flexible
enhanced by ABB’s extensive batch automation expertise. batch production facility there could be one or more
800xA Batch Management delivers: conditions that are dependent upon the type of material
being processed in the unit. Only 800xA Batch Management
−− Increased product consistency resulting in better quality provides exception procedures as an extension of the ISA88
− − Easy to use recipe management functions reducing time- procedural model to provide the ability to configure recipe-
to-market specific error handling logic. An exception procedure monitors
− − Integrated production management and control for for undesirable product related process conditions and
maximum equipment utilization and minimized operating contains corrective measures in case the conditions occurs.
costs
−− Regulatory compliance through the use of embedded 800xA Batch Management includes five primary functions:
system technical features
−− Definition management
−− Execution management
Functional area overview −− Resourse management
Any batch manager can sequence the process when steady- −− Data collection
state conditions persist and everything goes according to −− Displatching / scheduling
plan. What happens, however, when unexpected events
occur? 800xA Batch Management is the only batch control
solution that is uniquely designed to help recover from the
unexpected. The key to this is the flexibility that can be
designed into batch control strategies with System 800xA.

2 800xA Batch Management | ABB System 800xA

Definition management

Procedure All procedures are version managed with revision history

The master batch recipe procedure, and all nested procedure for each procedure. In addition to maintaining the approved
levels are configured graphically version online, a user configurable number of previous
in 800xA Batch Management. The following information can versions of the procedure are stored and are available online.
be specified for each individual batch recipe: A procedure revision history includes the User ID, full user
name, workstation node name,
−− Procedure date/time stamp, comments about the changes made and
−− Formula electronic signatures. The user is prompted to increment
−− Equipment requirements the version number each time a development procedure is
−− Header and other information promoted to an approved procedure. An online comparison of
any two versions of a procedure is available
Procedures are configured graphically using the Procedure via the difference report feature.
editor. The diagram is a Procedure Function Chart (PFC)
based on ISA88 standards. Strict adherence to the procedure Formula
levels specified by ISA88 can be enforced, or, for additional Formula information includes input parameters, process
flexibility, the procedure model can be expanded or collapsed. parameters, and output parameters. 800xA Batch
The procedure editor supports the configuration of conditional Management supports the specification of formula information
transitions, logical branching, parallel branching, looping at any level of the procedure. Formula parameters may also
structures and dynamic block labels for superior operational be specified as an expression, rather than a predefined value.
and control capabilities. This enables the dynamic, real-time calculation of recipe
parameters during the batch production execution. The ability
The procedure editor supports the creation and management of to dynamically calculate parameters provides tremendous
re-usable procedure building blocks. Unit procedures and opera- flexibility.
tion procedures can be used in multiple higher level procedures.
When a modification is made to one of these lower level proce- Equipment
dure building blocks, all procedures using that block are updated. Equipment requirements are specified within the procedure
using equipment allocation Batch Manager Action (BMA)
Only System 800xA provides Exception Procedures that blocks. The batch recipe can be configured to reserve
provide functionality above and equipment for subsequent batch processing, acquire
beyond the procedural model of ISA88. Exception procedures equipment for immediate batch processing, or dynamically
provide product recipe specific error handling at the batch select equipment from available equipment based upon
procedure level in addition to controller based exception and configurable selection criteria and attributes.
interlock logic.
Header and other information
The procedure header section provides administrative
information about the individual procedure. A procedure
description as well as free-form header text can be
Procedure Editor configured. The master recipe version, author, workstation
name and creation date are also contained within the header.
Standard operating procedures (SOP) can be defined and
associated to the procedure. If configured, they can be
invoked during the execution of the procedure and display the
SOP applicable to the current step in the procedure.

ABB System 800xA | 800xA Batch Management 3

Execution management

800xA Batch Management supports the simultaneous on the PFC. The current status of each procedure step is
execution of multiple control recipes in parallel. The represented by a unique combination of colors and symbols
configured and approved master recipe procedure becomes as the batch executes.
the control recipe procedure when the batch has been
assigned a Batch ID and dispatched for production. In addition to monitoring, the control recipe PFC display
Control recipe execution may proceed in one of three provides a number of navigation and interaction options,
operating modes; automatic, depending on the rights and permissions of the currently
semiautomatic or manual. logged on user including:

In automatic mode, procedural elements automatically −− Navigating to a higher or lower level of procedure function
execute sequentially through the procedure steps when chart
the transition condition following the procedural element −− Changing the operating mode (automatic, semiautomatic,
is satisfied. 800xA Batch Management communicates or manual) at any levelin the procedure
parameters, batch mode and state information to the −− Changing the state (running, aborted, stopping, etc.) of any
equipment phases executing in the controller. 800xA Batch active procedure block at any level in the procedure
Management includes a standard phase interface to the −− Responding to pending messages, or electronic
AC800M controllers as all of the controllers from the ABB authentication requests
heritage process control systems (e.g. Symphony Harmony, −− Viewing formula information
DCI System Six, Advant and Freelance). −− Viewing header information
−− Navigating to pre-configured active equipment phase
800xA Batch Management provides the user with the ability aspects
to integrate equipment running on other controllers into
the batch control recipe. Function Phase Driver is a user
configurable application which maps batch states, commands System 800xA also provides simple to deploy graphic
and parameters between the batch server and user defined configuration objects that provide batch specific information
OPC points representing the interface to an equipment on process graphic displays and enable easy navigation to
phase in a PLC or other process controller. This feature is PFC or batch status displays.
quite useful in process applications that include one or more
process equipment skids that are supplied and installed with Online recipe editing
equipment manufacturer supplied controllers. System 800xA provides unique online recipe editing flexibility
during batch execution. Authorized users can modify procedure
Batch execution monitoring sequence and equipment assignments as well as recipe parame-
The graphically based recipe procedure is available as a ters without stopping any executing control recipe. All changes
runtime display without any further configuration. During made to the control recipe are automatically saved in the batch
control recipe execution, its progress can be monitored production record.

Procedure Function Chart

Batch overview

4 800xA Batch Management | ABB System 800xA

Resource management

Equipment operational displays

800xA Batch Management supports network, multi-path and −− Equipment name and status (available, busy, reserved,
single path equipment configurations. This provides support acquired
of complex batch production facilities. The configuration of −− Batch, Lot and Campaign ID (when the equipment is
all units, shared-use equipment modules, and exclusive-use allocated to a batch
equipment modules is integrated with the common object −− Operating status (normal, diabled)
model of the 800xA system. This makes adding or “cloning”
a new process unit as simple as copy and paste. System
800xA is the only system that can use the new unit without The equipment information dialog is accessible from the
having to modify existing master or control recipes. Pseudo- Equipment Overview display. This dialog can be selected
resources can also be configured and used to identify for any batch equipment unit appearing on the equipment
resources, such as an operator, required at specified points in overview. The equipment information dialog presents current
a procedure. status and provides the user with the ability to manually
allocate the equipment, or remove it from service. The
In addition to the equipment allocation BMA procedure equipment specific attributes are also available for viewing
blocks, all other resource management functions are from this dialog.
accessible from the Equipment Overview display. The
following information is presented in tabular format:

ABB System 800xA | 800xA Batch Management 5

Data collection and tracking & batch
scheduling and data collection

The interface function is deployed as a web service.

Web services are technologies that allow applications to
communicate with each other in a platform and programming
language independent mannger. A web service is a software
interface that describes a collection of operations that can
be accessed over the network through standardized XML
messaging. It uses protocols based on the XML language to
describe an operation to execute or data to exchange with
another web service.

The interface provides pre-defined function calls to provide

connectivity with 800xA Batch Management. Read function calls
acquire real-time data from the batch system. Write function
calls execute limited control over operations in the batch system.
Standard read function calls can be used to retrieve the
following types of information:
Batch schedule with history Scheduling display
options −− List of all active batches
−− Details from any batch listed in the batch overview
−− Details from any approved procedure
Batch scheduling −− Tag key (batch) data associated with the batch
The production scheduling and dispatching functions of −− Details from any batch equipment
800xA Batch Management are accessed from the Batch
Overview display. This display provides a summary of all the Standard write function calls can be used to perform the
batches in the current production queue. following operations:

The Batch Schedule window is used to add batches to the −− Schedule a batch, including values for some or all top-level
real-time production schedule or recipe parameters
queue, in an efficient and user friendly manner. Functions −− Change a previously scheduled batch, including start time,
available from the Batch Schedule window include: priority, mode, and parameter values
−− Change attribute values on batch equipment
− − Select recipe procedure
− − Schedule an individual batch or a campaign of multiple
batches In addition to the application programming environment
− − Duplicate a previously run batch provided in the batch schedule interface, System 800xA
− − Automated or manual entry of Batch ID is available with an optional certified interface to the SAP
− − Optionally enter Lot & Campaign IDs PP-PI module. The 800xA Enterprise Connectivity Solutions
− − Optionally enter scheduled start time Production Planning Connector facilitates the dispatch of
− − Enter batch specific parameter values Production Orders from SAP to 800xA Batch Management
and monitors the process data to prepare a production
response transaction back to SAP.
Batch web service interface
For many facilities, the production scheduling functionality Simple Batch and Parameter Management
provided in 800xA Batch Management is used to schedule Simple Batch and Parameter Management offers the user an opti-
the batch manufacturing. However, it is recognized that onal way to schedule batches and manage formula parameter
some organizations have supply chain management information without the need to access the Batch Overview.
solutions, enterprise resource planning systems or schedule Using Microsoft Excel a user is able to add and schedule batch
optimization software packages in place for the determination recipe procedures within the batch manager. In addition, formula
of shop floor manufacturing requirements. 800xA Batch worksheets can be added to the Excel workbook to manage
Management includes a schedule interface function to parameter lists.
facilitate the bi-directional transfer of data between 800xA
Batch Management and an external application.

6 800xA Batch Management | ABB System 800xA

History and evolution

Batch history / 800xA Information Management 800xA Batch Management can supervise controller phase
The batch related alarms and events are routed to the 800xA logic in Harmony Bridge Controllers. The existing equipment
System event system for collection and organization by 800xA phase logic configured using Batch90 and resident in
Information Management. PHASEX function codes can be reused without modification.

The Production Data Log (PDL) history function of 800xA 800xA Batch Management can supervise controller phase
Information Management provides hierarchal history of logic configured in TCL resident in either AC460 or SC
batch data and events. Often in batch process applications, controllers. The existing TCL equipment phase logic is
information relationships cannot be pre-configured because retrofitted into the S88PHASE TCL template for 800xA Batch
they typically depend on the control recipe execution, Management. This is included with System 800xA for MOD
rather than on some periodic time basis. The PDL of 800xA 300.
Information Management has built-in provisions for the
organization, storage, archive and retrieval of this type of 800xA Batch Management can supervise controller phas logic in
information. DCU controllers. The existing equipment phas logic configured
using CCL can be reused whithout modification.
The data records stored in 800xA Information Management are
exactly accessible to Microsoft Access, Microsoft Excel, and other Functionality to meet regulatory requirements
popular reporting packages like Crystal Reports. Batch Manage- For manufacturing processes subject to licensing and
ment includes standard report templates that can serve as a basis inspections by regulatory bodies such as FDA, MHRA, TGA,
for configuring detailed, application specific batch production the Industrial IT Extended Automation System 800xA provides
reports. the tools needed to achieve compliance. Security, autdit
trail, change management, electronic signature, automated
With batch event data stored hierarchically in PDL, it is easy to reporting, archival and retrieval are integral to all operations
perform batch-to-batch analysis of trend data using associations and system applications. 800xA Management enforces the
to batch data to select desired batches and trend variables for production sequence necessary to consistently produce
anaylysis. -on-spec product. In combination with 800xA Information
Management complete electronic batch production records
Evolution that fully document manufacturing compliance are generated.
ABB has been a pioneer and leader in the design and
deployment of batch automation systems on a worldwide
basis. ABB has a twenty-five year heritage in the design of
batch automation system products and solutions for the fine
chemicals, food, beverage and pharmaceutical markets.

800xA Batch Management, like all functional areas within

System 800xA, has been designed to support the stepwise
evolution of existing process control systems. As part of a
facility’s evolution strategy, one option is the introduction of
System 800xA while retaining the existing controller and its
existing control strategy.

ABB System 800xA | 800xA Batch Management 7

Contact us

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