Campaign management orchestrates batch resources

Frequently a void exists between enterprise scheduling systems and the control and automation systems on the plant floor. Filling that void allows timely sharing of order status information with customers and vendors. In batch processes, filling the void is referred to as ‘campaign management.’

Fisher-Rosemount Systems’ (Austin, Tex.) Campaign Manager is the latest addition to the growing suite of applications and capabilities developed for the DeltaV scalable control system and provides a tightly integrated, easy-to-use batch campaign creation and management interface.

Once installed, Campaign Manager self configures from batch recipes already in the DeltaV database. Creation of a new campaign requires entering:

A batch campaign name;

The number (1 to 9,999) of batches to make;

The maximum number of batches that can be active at the same time;

A batch ID prefix identifier;

The starting batch ID sequence number; and

A batch ID suffix identifier.

All that remains is to click on the ‘Select’ button and choose from the existing batch recipes to be included in the new campaign. Besides product-related recipes, each campaign can include separate recipes for setup and cleanup activities frequently required with batch processes.

Because of Campaign Manager’s tight integration with the DeltaV Batch product suite, configuration to collect and save campaign creation, modification, and execution data is not required; it happens automatically and is forwarded to DeltaV’s Batch Historian (see CE , Nov. ’99, p. 94).

Since batch campaigns can take several days or weeks to complete, there is a chance production requirements or plant equipment availability will change. Campaign Manager facilitates adjustments to changing conditions by allowing operators, with appropriate security privilege, to add additional batches, remove batches not yet released, and make changes to the recipe, formula, or equipment specification for one or more batches defined within a campaign.

Campaign Manager’s three execution modes optimize batch executive performance for each defined batch and address different plant operating philosophies. The modes follow.

Manual requires each batch to be manually re-leased to the batch executive and manually started;

Auto release automatically releases each batch to the batch executive, but requires manual intervention to start each batch;

Auto start is the ‘lights out’ approach, releasing and starting batches until an operator intervenes, or all batches in the campaign are completed.

Sophisticated batch users often seek capability to duplicate operator capabilities with programmatic capabilities. Consistent with DeltaV’s extensive use of OPC (OLE for Process Control) and other open system integration tools, the entire DeltaV Batch product suite, including Campaign Manager, supports user integration requirements.

Enterprise integration

Present manufacturing watchwords are ‘make-to-order,’ flexibility, and agility. Users must rapidly and accurately share what’s happening on the plant floor with customers and vendors via enterprise databases and planning systems, such as Oracle and SAP’s R3.

DeltaV’s Campaign Manager Application Program Interface (API) provides the functionality needed to create, modify, and execute campaigns using data from external programs. Using the predefined API functions provided, users can automate scheduling and execution.

For more information, visit www.controleng.com/freeinfo .

Author Information

Dave Harrold, senior editor, dharrold@cahners.com

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