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On-line Quality Analysis Integration in Batch Process Operations Jean Vieille, Consultant INTERKAMA / ISA On-line Quality Analysis Integration in Batch Process Operations Jean Vieille, Consultant INTERKAMA / ISA TECH 1999 Düsseldorf - October 20 th 1999 Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 1

Overview 1) 2) 3) 4) 5) 6) 7) Context - Quality control in SCM Overview 1) 2) 3) 4) 5) 6) 7) Context - Quality control in SCM Scope and Goals Quality analysis process Process overview Production control activity Analysis activity QA results and material adjustment validation 8) Conclusion Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 2

Context • Polymerization Plant • ERP retrofitting – Enterprise / Control system integration – Context • Polymerization Plant • ERP retrofitting – Enterprise / Control system integration – Inventory management & Resource usage optimization – ERP mastering for Material, Production rules & Quality Control – LIMS out of date Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 3

Quality Control in SCM • Agile behavior, allowing: – specific customer requirements – last Quality Control in SCM • Agile behavior, allowing: – specific customer requirements – last minute changes • Match customer quality specifications at the lower cost • Track and record details, Report consolidated results • Do not slow down processes Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 4

Scope QC QC Production QC Goods Reception Jean Vieille Packing QC Warehouse INTERKAMA ISA Scope QC QC Production QC Goods Reception Jean Vieille Packing QC Warehouse INTERKAMA ISA TECH 1999 DUSSELDORF QC Shipping Slide 5

Goals • Quality Management – Flexible – Consistent mastering (ERP) • Process Knowledge – Goals • Quality Management – Flexible – Consistent mastering (ERP) • Process Knowledge – Recover human knowledge – Track Process behavior • Predictable performances – Reproductible – Human independant Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 6

Quality analysis process (LAB) QA Production Schedule Data to Plant QA Specs QA Status Quality analysis process (LAB) QA Production Schedule Data to Plant QA Specs QA Status LAB Sampling QA Status, Adjustments Production Performance QA Results Data from Plant PRODUCTION – PACKING - SHIPPING Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 7

Quality analysis process (Plant) Production Schedule Production Performance Data to Plant QA Specs Plant Quality analysis process (Plant) Production Schedule Production Performance Data to Plant QA Specs Plant LAB Sampling Results, Adjustments Data from Plant PRODUCTION – PACKING - SHIPPING Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 8

Process overview (Synthesis) RM RM Reactor PC LC Diluteur LC PC : Plant Control Process overview (Synthesis) RM RM Reactor PC LC Diluteur LC PC : Plant Control LC : Lab Control Jean Vieille Truck Loader LC Storage INTERKAMA ISA TECH 1999 DUSSELDORF Slide 9

Initial production schedule Production Request QA Requirement Material Requirement Segment Requirement Equipment Requirement (Class Initial production schedule Production Request QA Requirement Material Requirement Segment Requirement Equipment Requirement (Class based) Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 10

Operational production schedule QA Requirement Production Request Analysis Request Material Requirements Segment Requirement Equipment Operational production schedule QA Requirement Production Request Analysis Request Material Requirements Segment Requirement Equipment + Personal Requirement Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 11

Operational Material Requirement QA Requirement Adj. Formula Analysis Request QA test specifications Material adj. Operational Material Requirement QA Requirement Adj. Formula Analysis Request QA test specifications Material adj. request QA test result (Init)Material Requirement Unexpected material usage (Act)Material Requirement Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 12

Production performance report Production response Production request Segment Response QA Actual Jean Vieille Material Production performance report Production response Production request Segment Response QA Actual Jean Vieille Material Actual INTERKAMA ISA TECH 1999 DUSSELDORF Equipment Actual Slide 13

Quality Analysis activity schedule History Analysis Response Schedule Analysis Request Performance Analysis Response • Quality Analysis activity schedule History Analysis Response Schedule Analysis Request Performance Analysis Response • Historical results comparison for : – – Same product Same or any equipment Based of one batch or statistical Textual or graphical information Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 14

Material adjustement likelihood Material adj. (History) Material Balance (actual) Basic Formula (Includes adj. ) Material adjustement likelihood Material adj. (History) Material Balance (actual) Basic Formula (Includes adj. ) Material adj. Validatation Test Results (History) Jean Vieille Test Results (Actual) INTERKAMA ISA TECH 1999 DUSSELDORF Test Specification (Actual) Slide 15

Graphical control Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 16 Graphical control Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 16

Conclusion + : A great project… • Consistent System architecture • • Automated QA Conclusion + : A great project… • Consistent System architecture • • Automated QA business process: responsive and error free. Complete information, sample granularity at the plant level Summarized, validated information transfered to ERP Tight coupling between production rules, material handling and Quality control • Loose coupling between ERP and production system • Powerful likelihood and validation control. • Fluent adjustment process • Operator becomes more responsible and knows what he does and what the others have done. • Labs and operators work together. • Efficient Lab work management environment • FCS could be easily implemented Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 17

Conclusion (-) : …so what? • Wrong roots: • 100 % custom made, budget Conclusion (-) : …so what? • Wrong roots: • 100 % custom made, budget restrictions: predictable technical, financial and timing issues. • DCS stilll isolated • Standards not enough considered (S 88 and S 95) • Sorry… • The project should have been completed for long today allowing to speak about outstanding benefits and interesting issues… • … but this part of the project is still under development 1. 5 years after the final specification release… • No feedback available • We hope • You take the most of these ideas… Jean Vieille INTERKAMA ISA TECH 1999 DUSSELDORF Slide 18