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How can you be sure that operators will follow SOPs Standard Operating Procedures? Using an Industrial WorkFlow management tool such as GEIP Procify WorkFlow. This paper was presented at ANIPLA conference in Milano April 20th, 2010
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Workflow, ovvero “Come possiamo essere sicuri che tutti seguano (correttamente) le procedure di produzione?”
Enzo M. [email protected]
2 /GE /
April 13, 2023
Le prime istruzioni da seguire… (manuale operatore?)
All’inizio….
Infrastructure
Finance Media
3 /GE /
April 13, 2023
…ai giorni nostri
Infrastructure
Finance Media
Quante informazioni (e quanta… confusione?)
4 /GE /
April 13, 2023
Quanti processi ci sono in Azienda? In quanti sono coinvolte “persone”?
Ricevimento Materiale
Controllo Qualità
materia prima
Analisi/QualitàProdotto finito
Metal Detector CheckSetu
p Macc
hine
Azioni Correttive
Deviazioni Prodotti
Quarantena
Prodotti
Confezionamento
Prodotto finito
Stoccaggio materiale
Ges
tion
e Al
larm
i
Distribuzione Ordini in Produzione
Valutazione
Scarti di produzione
ControlloRi-lavorazioni
Puliziamacchine
Impostazione target, set-point
Calibrazione
Taratura
Schedulazione/Lancio Produzione
Business Process & Work Process Managementnelle Aziende Industriali (secondo il modello di ISA s95)
Level 4
Level 1
Level 2
Level 3
Business Planning & Logistics
Plant Production Scheduling,Operational Management, etc
Manufacturing Operations Management
Dispatching Production, Detailed ProductionScheduling, Quality Assurance, ...
DiscreteControl
BatchControl
ContinuousControl 1 - Sensing the production process, manipulating
the production process
2 - Monitoring, supervisory control and automated control of the production process
3 - Workflow / recipe control, stepping the process through states to produce the desired end products. Maintaining records and optimizing the production process.
Time FrameShifts, hours, minutes, seconds
4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels.
Time FrameMonths, weeks, days, shifts
Muro del Real-Time (firewall?)
ERP <-> Production System
Production Order Completed
Backflush InventoryMaintenance ExecutionActual Production Order
Status
Production Order Dispatching
Engineering and Spec Changes
Corrective ActionMaintenance
Task Management
Digitized Work Instructions
Task ExecutionStation-Level Control
Manual Data Entry
Alarm Analysis/ and Action
Mfg Intelligence DataCondition Monitoring
Wor
kflo
w
6 /GE /
April 13, 2023
Data Models – ISA s95 Compliance
• Equipment Model• Personnel Model• Material Model• Product Definition• Product Parameters• Personnel Specifications• Equipment Specifications
• Material Specifications• Process Segments• Product Segments• Work Order
7 /GE /
April 13, 2023
Proviamo ad immaginare se…Il nostro migliore operatore:
Fosse al lavoro 24h su 24 / 7gg su 7 / 365 gg all’annoPrendesse sempre le decisioni giuste seguendo le procedure di produzione approvate dal QA e secondo gli standard definitiSi incaricasse di produrre sempre rispettando i tempi, ai costi preventivati e secondo il miglior livello di Qualità raggiungibileCome?
8 /GE /
April 13, 2023
Cos’è un Workflow?
“L’automazione/digitalizzazione di un processo… durante il quale un’informazione o un task si muovono da un partecipante al successivo per far accadere un’azione…secondo una serie di regole.”
9 /GE /
April 13, 2023
Esempio di Procedura e WorkFlowUn controllo di qualità, manuale
Fare un prelievo del materiale per il QC
10 /GE /
April 13, 2023
3 Passi • Definire graficamente la logica
per l’esecuzione dei passaggi del processo e degli eventi/trigger del workflow
• Includere le interazioni manuali ed automatiche tra operatori, equipment e macchine
• Il Wokflow è pronto per l’esecuzione secondo quanto definito e con la raccolta dei dati e documentazione
Definire il WorkFlow per “Digitalizzare” la procedura di produzione
Il tutto senza doverlo “cablare” con il campo (con PLC/SCADA/DCS) e senza programmazione con strumenti e tool IT
11 /GE /
April 13, 2023
“Orchestriamo” tutti i processi di Produzione
Define Brewery Setup
WorkflowProcess Batch
Create/Modify Site Recipe
Create/Modify Master Recipe
Create Batch
Create/Modify Control Recipe
Process Batch
Complete Batch
Diamo visibilità al Processo
12 /GE /
April 13, 2023
Integrazione tra: Industrial Workflow & Process Automation (es. Farma)
13 /GE /
April 13, 2023
Alcuni dei più comuni casi affrontati: Work Instructions
- Electronic Work Instructions / SOPs- "Standard Work" for Lean Initiatives – “Error proofing”- Production Set Up- Virtual Trainer
Quality- Quality Hold: Non Conformance, Rework and Quarantine- QA Plan & Sampling
Corrective Action- Alarm Management and Corrective Action- Exception Management- HACCP Monitoring Procedures- Troubleshooting Trees: Equipment Repair & In-Process Product Repair
Middleware- Production Specification & Recipe Management- Industrial Middleware
Most Popular
Most Popular
Most Popular
14 /GE /
April 13, 2023
Service engineer(s) notifiedinstantly via wireless device
Fault combination triggers workflow(s)
Priority WorkOrder(s) issued
Supervisor escalation SMS/e-mail if no response
30mnlater
SignalFailure
Condition monitoringpicks up on failure
Faults reported .Require simultaneous action
ELLIPSE work planning system notified with feedback
Engineer guided through requiredactions on wireless device
Workflow Acknowledge & Dispatch
Work Orderclosed
Supervisor report issued as e-mail
Data recorded for Auditing& Data analysis
ELLIPSE work planning system notified of completion
Spare parts orderedas required
Esempio di manutenzione in linea 1
15 /GE /
April 13, 2023
Flag raised in Historian toinitiate maintenance activity
Motor VibrationCondition monitoring
picks up on failure
Supervisor escalation if no response
30min later
Engineer(s) notified viawireless device
Priority WorkOrder(s) issued
Maintenance Work Ordergenerated in Maximo / SAP PM
Fault combination triggers workflow(s)
Work Orderclosed
Supervisor report issued as e-mail
Material consumption reported& spares ordered as required
Engineer guided through requiredactions on wireless device
Work Order inserted into productionschedule as required
Workflow Acknowledge & Dispatch
Data recorded for Auditing& performance analysis
Asset Mgt System (Maximo/SAP PM) notified of completion
Esempio di manutenzione in linea 2
16 /GE /
April 13, 2023
Esempio ApplicativoAcquedotto (City of Haverhill)
• Electronic Standard Operating Procedures>Emergency Response Plan>Version Compliance
• Alarm Management• Employee Training• Quality Sampling• Exception Management• Middleware
17 /GE /
April 13, 2023
Esempio Applicativo:Depurazione/Trattamento Acque Reflue• Electronic Standard Operating Procedures
>Wet Weather Event Response• Alarm Management• Employee Training• Quality Sampling• Exception Management• Middleware
18 /GE /
April 13, 2023
Esempio Applicativo: CPG Prodotti per l’igiene personale
• Electronic Standard Operating Procedures• Alarm Management• Line Change-Over• Middleware
19 /GE /
April 13, 2023
Asempio Applicativo: Life SciencePfizer - Capsugel• Electronic Standard Operating Procedures
• Alarm Management• Quality Sampling
>Collection too slow• Line Change-Over• Middleware
“Capsugel chose Proficy Workflow because it is an innovative product and essentially can do what no other product on the market can do.”
- Rovisys
20 /GE /
April 13, 2023
Esempio Applicativo: ChemicalSABIC Innovative Plastics
• Electronic Standard Operating Procedures• Lean Production Initiatives
>Waste Identification>Process Improvement
• Exception Management• Middleware
21 /GE /
April 13, 2023
Esempio Applicativo: Produttore Internazionale di Birre
• Electronic Standard Operating Procedures• Alarm Management• Employee Training• HAACP• Quality Sampling• Line ChangeOver• Recipe Management• Rework Instructions• Exception Management• Middleware
22 /GE /
April 13, 2023
Il contesto delle applicazioni industriali WorkFlow & SOA
SOAinc. 3rd party
23 /GE /
April 13, 2023
iFIX
Change M
gt
Batc
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xecu
tion
Pla
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Ap
plic
ati
ons
Data
mart
Main
t. G
ate
way
Trou
ble
shoote
r
Track
er
His
tori
an
Port
al
Sch
edule
r
Work
flow
Open E
nte
rpri
se
Data
/Equip
. M
odels
Even
ts
Proficy SOA
Modules Services
HMI Historian Workflow MES 3rd PartyApplications
Cim
plic
ity
SOA: Service Oriented Architecture
24 /GE /
April 13, 2023
SOA: Service Oriented Architecture
