O F INTELLIGENT RECIPEMANAGEMENT"
"THEBENEFITS
D de Kerf
Nijverheidsstraat 1
4551 LA Sas van Gent
The Netherlands
ddekerf@nl.ebsworld.com
Abstract - This paper describes advanced process
management features of Intelligent Recipe Management
compared t o the conventional Recipe Management
Solutions. Aspects that are mentioned are dynamic
optimization of set points, dynamic control recipes and
the integration of the process in the total supply chain.
The benefits of each of these features in a typical blend
application are mentioned, too.
I. SUMMARY
Computer based support systems throughout the enterprise
must be able to respond immediately in order to support the
dynamic business objectives of today global enterprises.
Trends like e-business, Customer Relationship Management
and Supply Chain Management can only be supported if the
business support systems are able to communicate in an
economical way with the support systems that are used in
modem Manufacturing organizations. Since most applications
are not designed with that requirement in mind this integration
is very hard to achieve.
Besides that most manufacturers consider the plant as the
bottleneck in the supply chain. Traditional batch management
applications are not always designed with enterprise
application integration in mind.
Another common i s u e is that most advanced batch
management systems cannot be applied to generic batch
processes. In order to improve the efficiency of software
investments it would be useful to apply one common base for
all Recipe Management applications throughout the
corporation. Since virtually every modem Recipe
Management solution is able to apply the ISA S88.01
approach there seems to be a part of every application that
might be considered as common. However the S88.01
standard does not support some necessary advanced control
solutions: dynamic control recipes (optimized workflow and
set points based on business rules) are not really mentioned
in this well-known dictionary.
This paper describes the advantages of tailor made
applications that are build with common modules. The
described application is based on open systems and proven
technology. It is supported with examples that are based on
real life shop floor experience. The human factor is not really
addressed in this paper: it was, is and will always be the main
reason for a lasting success.
11. INTRODUCTION
There is no clear definition of Intelligent Recipe
Management. Conventional Recipe Management Systems are
in most cases not part of the supply chain. The shop floor
might as well live in an entirely. different world than the non-
manufacturing organizational entities. People and systems
0-7803-74460/02/$17.00 02002 IEEE - 168 -
M Jhaveri
Cerestar, USA
1100 Indianapolis Blvd.
Hammond. IN 46320
USA
retype (with or without a conversion) the same data many
times. As soon as the manufacturing facility is really
integrated in the business processes we already have
achieved some improvements compared to the bulk of the
current work systems.
The earlier mentioned rework also takes place within the
organizations itself. Standard office applications like Microsoff
Excel are used by most of the engineers; managers and
operators to report results or to compute optimized settings.
The advantage of the use of this common software is its
degree of flexibility. People are able to customize this kind of
applications to a big extent without the help of IT experts.
Since most manufacturers want to focus nowadays on the
core business and IT experts are either too expensive or not
available the support of common office tools in the control
applications might help us to improve our processes with less
effort. Domain experts don't have to explain a programmer
what they want anymore in these cases.
An Intelligent Recipe Management System is the ultimate
intermediate system between the process control application
and all other support systems that are used in respect to the
application; it processes data from other work systems and
provides feedback for them. Some examples of these external
work systems are planning, quality support systems,
specification systems, batch reporting, tracking systems,
calculations and many more.
Modem, proven information technology is not always used
in a very effective way. Traditional control engineers are not
exploiting the available mass technology that is already
applied in most business applications for many years to its
utmost. Business System Analysts seems to lack the
knowledge to implement a combination of proven IT solutions
in a generic set of modules that can be used as a starting
point to support every real life Recipe Management Solution.
The misunderstandings between traditional control engineers
and business analysts might limit the potential effect of
business cases on the entire corporation. System integrators
who can link both application domains seem to be the ones
that can overcome the current barriers.
One of the biggest problems in applying basic modules for
more applications throughout the enterprise is that many
people assume that every case is special. What is special
about calculations, order processing, complaint handling,
quality management if all local applications are managed and
monitored by one corporate ERP system! There seems to be
enough similarity to use one corporate ERP system on top of
all the 'special" applications! Common modules must be setup
in such a way that local organizations can customize the
setup. The use of common technology lowers the barriers that
are created by common applications. Management support is
essential to ensure the success of local implementations
based on common standards.
Limiting the freedom and creativity of individual domain
experts is a serious thread to the practical success of an
application. The common architecture must support the
business process and give every individual expert enough
possibilities to personalize an application. In order to ensure
the required support of every organizational unit it iS very
important to agree on a common dictionary, common
requirements and common procedures.
Time is another important factor. People must have the
chance to get used to new approaches. The support of each
individual expert takes time but it is worth the effort: business
can only improve if everyone supports the commonly applied
strategy because they believe in it.
The international project that is the basis for this paper was
dealing with four different applications spread around on three
continents. The project included the following generic steps:
create inventory, define common definitions and rules, define
common requirements, define responsibilities, agree on
requirements document, get management approval, develop
the common modules and implement them in two of the four
earlier mentioned applications. The international multi-
disciplinary team had representatives aboard of all
participating factories.
111. DEFINITIONSAND RULES
Generic blend processes are used throughout the entire control recipe. A control recipe is always ended with a
industry. Standard operating procedures that are used in the
specific applications often show big commonality from a
conceptual point of view.
Every process complies with one common workflow:
someone or something gathers information about the current
status and the results that must be achieved. Based on this
input a decision is made how to proceed in order to achieve
the objectives in one way or another. Than the agreed set of
actions is executed. When all actions are completed we start
all over again. In most cases we must check whether the
result of our actions is as expected. Based on the results we
decide what to do next.
Batchiparameter driven applications share common issues are often very similar:
as well: the available materials must be used to its extent and -
the capacity of the installation must be used as efficient as
possible. This forces us to look carefully at the quality and -
availability of ingredients and the possibility to reuse -
remnants or intermediate products.
In order to achieve these objectives with one wmmon
platform for applications throughout the enterprise it is very -
important to agree on common definitions and rules before the
actual requirements are discussed and agreed upon. It is part -
of requirement definition process and crucial to ensure a
common set of requirements that is supported and understood
by everyone practical for every application. Creating an when the quality parameters and ingredients are known it is
inventory of the existing or required might be an excellent start not recommended to put more than one intermediate product
for this kind of activities.
Although ISA S88.01 defines the basic wmmon
terminology already it is far from complete: business rules are in the previous paragraph. Since the quality and composition
not mentioned in this kind of standards. Some examples of
fairly generic additional definitions are listed in the next
paragraphs. It is remarkable how often (or is it: how seldom)
local experts shares thoughts and experience with colleagues car. holding tank, scrap tank...)
in other departments or shifts. A common vocabulary is a
necessity for a good understandingof the requirements.
A basic comDonent is a defined product from an internal or
external supplier that is labeled by a unique product code and
used in prescribed recipes to produce a batch.
A grade chanae DrOduct is the intermediate product that is
produced during a grade change procedure within a
production channel. It does not fit the quality specifications of
both products.
A remnant is the product that is left in a unit when no further
load-out or transfer should be done. It might be the result of
corrections. a failed batch and an inaccuracy in the dosing
system, legal restrictions of the maximum truck weight or any
other reason not to transfer a part of the produced lot.
A master reciDe is the process cell dependent site recipe
that is defined in the corporate specification system.
A control reciDe consists of all procedures and parameters
that must be executed in order to produce a batch. The
control recipe is generated from a master recipe and adapted
to the scheduled batch by the calculation module.
An alternative recipe enables us to produce a batch in an
altemative way. Every authorized master recipe that is defined
in the specification system might be used to produce a
product.
A correction consists of all procedures that are required to
bring a batch within the specified limits after the initial control
recipe is ready. These actions will be gathered in a new
sampling procedure.
The above mentioned examples are used in the definition
of the common rules (e.g. standard operation procedures).
Some examples are described in the next paragraphs
In order to be able to handle the inaredients the important
quality parameters of the ingredient must be known; this
implies that every basic component that is permitted in a
storage tank is considered to be within agreed specification
limits ("in-spec"). This enables us to simplify the calculations
that are needed to generate a control recipe.
An authorized procedure how to handle intermediate
pr~&@is important, too. The generally used local procedures
the basic components are known
- take a sample of the lot
determine the quality parameters
check whether the ingredient is mentioned in the product
specifications of scheduled batches that have not been
started
check whether the quality assurance department allows
the use of intermediate product for the customer
use a limited amount of intermediate product in the
batches that meets the last mentioned requirements
Although it is possible to forecast the composition of a lot
(i.e. two basic components) in a tank.
The use of remnants is similar to the procedure described
is already known it is not needed to take a sample to
determine how to use the lot. If the remnant cannot be used it
must be transferred to another storage location (e.g. a bulk
- 169 -
 IV. MODULES
A generic intelligent recipe management system is an
intermediate operational system that:
- automatically receives the necessary input from other
(administrative and manufacturingsystems)
- supports manual data entry if one of the automated
interfaces is disabled or not working properly
- pre-processes batch data and determines control recipes
- downloads control recipes to the Open Control System
- provides a central user-friendly human machine interface
for the operator during normal operation
- supports tracking and tracing
Automatic systems cannot handle all situations. An
important design requirement is that the operator must always
able to take over the control of the Intelligent Recipe
Management system on both the system itself and on the
Open Control System.
I
J i l The graphical user interface enables the operator to:
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inventay
IntElhce
Fig. 1: Intelligent Recipe ManagementFramework
A. Process Model
All physical equipment is configured in the process model.
The other modules are using this source to get the current
configuration: the graphical HMI, calculator, workflow
manager and OCS interface derive most of their configuration
input directly from this source. The interface to the
Specification Management System stores its data in the
products and master recipe database. In order to achieve a
certain behavior the process model can differ from the
physical model.
8. 8afch Confml Center
The batch control center can be considered as the core of
the common batch production system. This module:
- processes the requests from APS and triggers the
necessary actions that are required according to the
request
- processes the events from the OCS and triggers the
necessaiy actions that are required according to these
request
- 170 -
provides a user-friendly graphical human machine
interface for all actions
provides a sequential function chart for every control
recipe
logs every action that is initiated in the batch production
system
Is the main operator Interface during normal operation. It
is very important that the local process control
applications support external connections for every user
interaction that it supports itself
view the actual status of the process
view the detailed status of a unit
view the current status of a recipe using a Sequential
Function Chart as it is defined in the S88.01 description
C. Automated WoMow
The Intelligent Recipe Management system supports the
actual workflow on the shop floor. The essential workflow of
any process consists of the following steps:
- define the required result
- check what is available andlor possible to achieve this
result
- define and approve the set of actions that must be
executed
- execute of this control recipe
- check whether the set of actions was successful
The above mentioned workflow applies to handle batches
and orders from the APS (Advanced Planning System)
system and to operating procedures that are triggered by the
operator without an offcial request from the APS environment.
An example of such a manufacturing operation is to empty a
tank completely or to transfer material from a storage tank to
another storage tank.
Eveiy event that happens in the process must have a
unique identifier. The APS system only supplies identifiers for
a batch or an order. Corrective actions or manufacturing
operations are not known in the APS application. The
Intelligent Recipe Management system has to assign a unique
identifier to every control recipe that is uploaded to the Open
Control System. Adding a sequential number to the identifier
that is supplied by the APS system is a practical solution.

Every control recipe will have its own identifier in this case.
Since the original APS identifier is part of this internal ID it is
not too difficult to use the historical data of the Intelligent
Recipe Management system for tracking purposes.
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The state diagram for a control recipe as it is defined in the
ISA S88.01 standard can be applied without any change. The
batch itself has no separate state diagram. Internal checks
might prohibit the operator to start a new APS batch before
the current batch is formally completed.
D. Calculator
The calculation module:
computes the parameters that are required in the Open
Control System to produce a batch
computes the parameters that are required in the Open
Control System to execute the scheduled load-out
procedures
supports initial calculationsand corrections
supports calculations based on the defined mean
specification that can be derived from specification
system
supports calculations based on the known composition of
components
supports combinations of the two earlier mentioned
approaches
is able to handle last known values derived from LIMS.
mean values derived from the specification system and
moving averages derived from the last known series of
values in LIMS
converts recipe parameters if needed
stores the results in a generic format in the control recipe
buffet
The calculation module is using different inputs for the
same calculation in different circumstances:
- the initial control recipe is based on the mean values that
are defined in the master recipe
- the operator is able to set the importance of the
parametersthat are used in the calculation module
- it is akays possible to initiate the generation of a control
recipe on operator request
- 171
Almost any procedure that is used to optimize the recipe
parameters can be computed using Microsoft Excel. In
practice we can define different calculation types:
- Use one attribute from a single lot as an input and return
one set point to the Intelligent Recipe Management kernel
- Use more attributes from more than one lot as an input
and return multiple set point to the Intelligent Recipe
Management kernel
All actions that are supported by Microsoft Excel can be
used in the calculation. The standard solver can already
optimize the recipe parameters of many applications that are
in use. If the number of input and outputs in the solver is
exceeding a certain limit one can always consider deploying
another commercially available solver that can be used in
Excel.
Fact is that many engineers use Microsoft Excel to
preprocess optimizations (on the shop floor and on their
desk). The support of the Excel format makes life easier for all
of us in these cases. The Intelligent Recipe Management
system defines a standard format for the input and output
sheet. It is up to the user to make use of histher knowledge to
implement whatever Excel allows himlher to do.
Evew spreadsheet represents a method that must be used
under certain circumstances. The naming convention of the
worksheet can be used by the system to determine when to
use a integrating the name (e.g, pH),
method (e.g. too lowor too high) and fieproduct name (e.g.
sodium) in the file name is one way to implement this, This file
name algorithm does not make for the earlier
. .product-multioleattribute method.
mentioned multiDle
In many cases a produa can be made using another
master recipes. Some ingredients are interchangeable as
well. These alternative basic components are configured in a
separate source. They are used in the earlier mentioned
multiple product-multipleattribute spreadsheet.
One important issue must be taken into account: however
how complex the background calculations the operator
interface must be simple!
Fig. 4: Calculator
Besides the parameter optimization the calculator is also
optimizing the order of the phases in the control recipe. Since
the ISA S.88.01 does not support this kind of batch operations
at this moment this optimization will not be discussed in detail
in this paper. The entire system is designed to support the
dynamic control recipes based on rules that can be set in the
system configuration. Some possible optimizations are:
- Optimize the dosing of the different ingredients
- Start the homogenizing at the best moment
- Combine heating and cooling operations
E. Inventory
The inventory stores all quality and composition data of
each lot. The quality data is gathered from the LlMS system,
the composition is automatically updated when material
transfer events from the OCS are received. The composition
of a lot describes which basic components and how many of
them are in a lot.
Every lot or traceable material has a unique identifier. The
configuration in the process model defines whether a new lot
will be created when a new' sample is requested or new
sample result is received from the LIMS.
The inventory is the basis for all calculations. It takes all
reservations of approved control recipes into account. The
reservations are deleted as soon as the material transfer
complete event from the OCS is received.
The calculator enables all possible sources automatically.
Criteria for enabling the material in a connected unit are:
- the lot must be homogenous (the quality results cannot
be used automatically when the lot is not homogenous
~ the products in a lot must be defined in the master recipe
(derived approved products like alternative basic
components are enabled as well)
In some configured cases the composition of a lot is
derived from the quality results automatically.
F. Interface to Advanced Planning System
APS is the responsibility of the Order Fulfillment
department. Manufacturing is allowed to update the batch
schedule under agreed conditions.
The APS interface module:
- processes the orders that are acquired from the
scheduling system
- prGprocesses the order data and stores the results in the
orders buffer
- supports manual input of the order data if the intelface to
the scheduling system is not available or disabled
The quality assurance department defines all quality issues.
Customer order related quality issues are stored in the
customer database (e.g. the CRM environment). This data is
transferred to the manufacturing application by means of the
order fulfillment department and is therefore included in this
interface.
The activities in most basic batch applications can be split
in two: basic batch processing and customer order handling.
Although both activities are executed using control recipes the
data and workflow that is required in both cases is differs.
Every generic recipe management system must support both
batch and order handling.
In most cases one batch is one customer order. Batches
can also be split in more orders and multiple batches might be
needed to create one order (e.g. train car!). The unique
identifier for a batch or an order must be the same throughout
all support systems! Tracking all events in the entire process
(from raw material to customer) forces us to take this issue
into account.
The APS software is the master of the batch schedule in
any case. There is no scheduler in the recipe system. It is
recommended to let operators under specific conditions use
172.
the same APS software schedule as the planners to
reschedule a batch. Rescheduling of load-outs can be done in
the process control software if needed.
Although APS is considered to be the common order
fulfillment scheduling software it is possible to consider the
described interface as a general order fulfillment interface for
manufacturing applications.
APS indicates the relationship between the blend and load
operations and separates combined operations in separate
items.
Since the module can be used for different batch
applications it is recommended to split the interface in two
parts. One generic batchlorder part (e.g. batch, quantity, latest
start time or latest possible end time) and a part with
application specific parameters (e.g. load out temperature or
maximum part of a certain type of intermediate material).
The Intelligent Recipe Management system reports me
actual status of the process back to the APS system. The
status of the units, batches and orders is passed back to the
APS. This enables the organization to implement a fully
dynamic APS environment.
G. Interface to Laboratory Information Management System
The LlMS environment is the responsibility of the Quality
Support department. Manufacturing is able to enter new
samples in LlMS and get the analysis results and statistical
calculations that are derived from these results from LIMS.
The LlMS interface module:
- processes the samples that are acquired from LlMS
- pre-processes the samples and stores the results in the
orders buffer or in the inventory
- supports manual input of the samples if the interface to
LlMS is not available or disabled
- announces new samples to LlMS when a correction is
started or an additional sample is required by the
operator
- defines the link between the samples and the orders
(load-out procedures)
Although LlMS is considered to be the common quality
support and quality control software it is possible to consider
the described interface as a general quality interface for
manufacturing applications.
A direct interfacing on sample level is not always the best
way to implement this interface. The time that is needed to get
results of some parameters within a sample can be different; it
depends on the method. In order to allow corrections for out-
spec parameters without any delay it is recommended to link
LlMS on parameter group level (e.g. dry solids or sugar break
down).
The quality verdict of a lot can be based on internal
manufacturing specifications, customer specifications or any
other available criteria. Misunderstandings a b u t limits (the
calculator is determining what actions must be taken to make
a lot in-spec according the applied criteria) are possible in a
real life application. Besides the overall quality verdict the
LlMS interface also returns the verdicts, applied limits
(according the internal manufacturing specification, a
customer specification or any other specification) and the
actual value of the each Darameter.
 ~
H. Interface to Specification Management System
The corporate specification environment is not the
responsibility of the shop floor organization. It defines the
approved master recipes. Manufacturing is able to get these
master recipes and is using them to generate the initial control
recipes
The Specification system interface module:
- processes the recipes that are acquired from
Specification system
- pre-processes the recipes and stores the results in the
master recipe buffer
- supports manual input of the recipes if the interface to
Specification system is not available or disabled
Specification Management is an emerging area. It is an
essential part of the business support systems. It is the unique
source that is required when specification data is shared with
internal and extemal contacts. The required globalization of
commodity businesses must lead to a certain efficiency
improvement if the organization wants to survive on the long
term.
1. Interface to Open Control System
The Open Control System interface module:
- pre-processesthe control recipes data that are defined by
the batch control center
- translates the control recipes to the local format of the
Open Control System
- sends the resulting control recipe to the Open Control
System
The recipe bufler in the Open Control System must support
dynamic control recipes. The Intelligent Recipe Management
system uploads the phase identifiers, the number of
parameters sent and the parameters itself. An additional
advantage of this approach is that the OCS can validate data
and that no programming is required when a new product
group is introduced that is using the same phases in a
different way; the local organization is able to implement new
master recipes without outside help.
Although most applications are still using polling as the
mechanism to communicate OCS data with other systems it is
recommended to use an event driven communication. The
disadvantage of polling is that certain fast events can be
missed. Events can be placed in a buffer and read at any
time. Of course. on operational environment has to respond in
a certain time period. Generic events are having a time stamp,
unit andor control recipe identifier and parameters.
A load-out is considered to be a generic transfer. There is
no difference between a material transfer from a storage tank
to another tank (the dosing of an ingredient) and the material
transfer from a unit to a bulk car, train car or another storage
location.
The re-use of leftovers can be handled as a normal transfer
if a "keep component" phase is implemented on the OCS.
This phase enables the engineer to use the same application
to compute the amount of leftover that can be used in the next
control recipe and to compute the amount of ingredients from
other storage locations.
The OCS interface must support transactions and
asynchronous operations. One example of a transaction is the
uploading of the control recipe. The OCS must wait with the
processingof the buffer until all data is sent.
173.
J. Interface to Weighing Bridge
The weighing bridge interface module:
- processes the weighing data that are acquired from
weighing bridge
- pre-processes the weighing data and stores the results in
the orders buffer
- supports manual input of the weighing data if the
interface to the weighing bridge is not available or
disabled
The law limits the maximum weight of a truck in most parts
of the world. The weighing bridge data will be used to prevent
that trucks are overloaded.
K. Application Support Tools
The documentation of shop floor applications is not very
adequate in many cases. Project managers tend to save on
documentation. Standard Operating Procedures for
production and maintenance are the minimum documentation
that is required. The amount of documentation that is really
needed depends on the service level agreement of the
application and the way the first and second line support is
setup.
Application support tools are a necessity to keep more
complex automation systems operational. Logging every
action is another crucial issue. It enables the organization to
keep track of everyihing that has happened in the facility and
is needed to determine what has really haDDened
Engineering support tools are neebed .as well. The design
of these more complex object oriented applications requires a
proper design environment. The modules rely on each other.
Their individual design must fit in the concept. Since the
implementation of this kind of applications involves many
different domain experts (process engineers, product
specialists, IT specialists, quality engineers, production...) the
communication between the different groups must be as clear
as possible. UML based tools like Rational Rose is a
requirement, not a luxury. It helps to make sure that the result
is according the requirements. It is no guarantee that the
project is finished on time and in budget!
v. APPLYING THE COMMON MODULES
Since almost any organization has common administrative
business support systems the interfaces with this ERP like
systems can be applied with little changes throughout the
enterpnse Most organizations have less harmonizaion as far
as Open Control Systems is concerned In order to minimize
the amount of different OCS interface it is recommended to
use open standards like OPC for this purpose. Although the
Alarm and Events part of this standard is originally designed
for SCADA usage it is also possible to use the interface for
the event driven feedback from the OCS that is described in
this paper. The current problems with the Automation
Wrapper that is provided by the OPC Foundation will be
solved on short notice. Until that problem is resolved some
restrictions apply: the amount of events that can be processed
in one go is limited to one.
It is recommended to base the entire framework on one of
the commercial available MES packages. The package can
be used as a toolbox. Some extensions must still be created
during the initial implementation (inventory, interfaces to
LIMS, specification management and APS). The basic
modules that are supported by every MES package (like
recipe management, process model and electronic batch
reports) can be used without any change. The challenge to
develop robust add-ons is difficult enough. Yet taking another
risk aboard by developing modules instead of integrating
existing soliware is not recommendable. The less special
code there is the bigger the chance that the application is
robust.
Evely extension that might be changed by the local
application support must be written in an easy-to-use
language like Microsoff Visual Basic. The kemel. which is
common and therefore not likely to be changed on request of
one application only, can bener be written in more flexible
languages like C.
A common framework enables an organization to re-use big
portions of an application (up to eighty percent) every time.
This reduces the risks that are associated with new
developments. Certain local customizations must be possible.
As long as the modules that can be subject to these local
customizations are cleady marked there is no problem.
The initial investment for a fully integrated system that
supports all the described functionality must not be
underestimated. Such a development project might cost up to
US$ 300K. Since conventional local applications with less
functionality has an average cost of US$ 450K the overalf
investment for the first project is still less than such a
conventional approach. Too many engineers and managers
underestimatethis type of advanced control projects.
Developing this kind of applications is not obvious. The
sample project started one and half year ago. The common
requirements document took us five months. The
development took place in two phases due to Y2K issues. The
actual development is completed since last June. We have
redesigned a part of the common modules at least one time.
Applying common rules in such a way that procedures are still
practical at the shop floor is a challenge as well. The project
manager dedicated at least one year exclusively to this
project.
VI. LESSONSLEARNED
The following issues must be kept in mind before
integration projects like the one that is described in this paper
are started:
- The scope must be well defined and not too big
- The team must consist of skilled IT engineers, process
engineers and process control engineers. All team
members must have experience with operational
applications
- The team must be able to consult domain experts
throughout the enterprise
Conventional design methods are not sufficient to create
~
this kind of environments
~ The team members must be dedicated to this project
during the critical phase: this is not the kind of activity that
can run in parallel with other activities
- The use of available soliware minimizes the risks. There
will be enough challenges left!
- Tests will take far more time then most people expect. It
is impossible to test every possible situation off-line. The
on-line tests must be planned carefully in order to
minimize potential problems in Production
- 174 -
VII. BENEFITS
An Intelligent Recipe Management as it is described in this
paper has the following advantages compared to conventional
systems:
- Improved overall performance: the first time right rate will
be improved because of the dynamic optimization of
recipe parameters based on known quality results and
the automatic interface to the other business support
systems. Less correction actions will be required. This
has a direct impact on the effective capacity of the
installation.
Improved Drofit marains (less waste product): the
~
automatic remnant and grade change handling ensures
that all material is used without interfering the overall
quality of a product. Since the profits on commercial
products are normally bigger than the one on waste there
is definitely a benefit. There is also a direct benefit
because of lower disposal costs. Depending on the
application (number of grade changes procedures,
amount per grade changes and the price levels) it might
have quite an impact. A mid-sized corn processing facility
makes at least US$ 1 million more per year due to grade
change handling only
- fullv documented process: the extended logging of all
events that take place in the application/process can be
used for analysis to trigger process improvements and
locate the source of quality problems
- shorter time to market: the configurable nature of the
entire system enables the user to customize a big part of
the local application without additional support
- Less capital investment: there is one generic framework
for multiple applications, most modules can be re-used.
The first implementation will cost as much as
conventional locally developed applications (around US$
450K).The second application can be setup for less than
US$ lOOK
- lntearation with SUDDIV olanninq: the tighter integration of
Advanced Planning Systems and the process might be
the foundation for further business improvements (re-
engineering kind of activities). The APS application can
update the planning automatically based on the feedback
from the Intelligent Recipe Management system
- Less customer comdaints: customer exclusions are
taken into account by the system. The automated
interlaces will minimize typing mistakes or other
misunderstandings that might arise when people has to
communicate
- Lower cost of OwnershiD: the framework can be applied in
multiple applications. Second line support specialists can
be used for several sites. An indirect benefit of a bigger
volume can be obtained by the purchasing department
VIII. ACKNOWLEDGMENTS
We wish to express our sincere appreciation to the
Cerestar (NWEA) BPS project team and to evelyone in
Europe and in America who has contributed to the BPS
projects.
IX. REFERENCES
[I] ISA-S88.01., Batch Control, Part 1: Models and
Terminology (ISBN: 1-55617-562-0)