Use Process Phases with Material Input Parameters

The following section describes process phases that have material input parameters.

Use Automatic Process Phases

When an automatic process phase with an input parameter is encountered in a recipe, Batch Manager evaluates the units available in the train and allocates a unit using the rules of allocation. The phase status is then evaluated and run when possible. The material information is stored in the historical database, but Batch Manager does not interact with the Materials Database for lot tracking information.

Use Manual Process Phases

When a manual process phase is encountered, Batch Manager is responsible for processing the phase. The phase does not run in the control system, although Batch Manager may use information, such as the Actual Value as measured by the control system in running the phase. The material information is stored in the historical database, but Batch Manager does not interact with the Materials Database for lot tracking information. Depending on how the phase is configured in the process model, operator interaction with the phase vary.

The following information describes various approaches that you can configure in the process model for manual process phases:

• Manual addition using a connected scale

  Material is weighed by a scale that is attached to the control system. The operator is required to enter the material lot code for the material if configured in process model. When the weight is within the material deviations, the operator acknowledges the completion of the phase. Batch Manager logs the material id, target quantity, actual quantity, and lot code to history.

  When the addition requires multiple lots of the same material, the operator must enter the lot code for the first lot and acknowledge the completion of the phase. Batch Manager decrements the actual quantity from the target, recalculate the target quantity, and re-run the phase. This occurs until the original target is achieved.

• Manual addition using an unconnected scale

  Material is weighed on a scale that is not attached to the control system. The operator is required to enter the material lot code if configured in the process model, enter the actual weight, and then acknowledge the completion of the phase.

  When the addition requires multiple lots of same material, the operator must enter the lot code for the first lot and acknowledge the completion of the phase. Batch Manager decrements the actual quantity from the target, recalculates the target quantity, and re-runs the phase. This activity occurs until the original target is achieved.

• Acknowledge addition of material

  In this approach, materials are pre-weighed prior to the final production. As materials are added, the operator acknowledges the addition of the material. Batch Manager records the material usage by using the target quantity as the actual quantity.

• Manual addition with scale and without scale

  The addition can have two parts (for example 60 pounds of salt must be added. Salt comes in 50-pound bags). A scale is attached to the control system. A 50-pound bag is added to the batch. The operator enters 50 as the actual quantity, enters the material lot code, and then acknowledges the completion of the phase. Batch Manager decrements the actual quantity from the target, recalculates the target quantity, and re-runs the phase. The remaining material (10 pounds) is weighed on the scale. When the weight is within tolerances, the operator must enter the material lot code and then acknowledge the completion of the phase.

  For the manual addition to function properly, control system logic must be designed to disable the scale input when the operator enters the actual bag weights. You could assign a control button to do this. The control button would disable the scale from overwriting the entered value.