FactoryTalk® Batch Software Suite Batch Management for Flexible Production Needs

The FactoryTalk Batch Software Suite, comprised of three key modules, enables you to develop batch control systems that support your flexible production needs. The key benefits of each module include: FactoryTalk Batch (pages 2-3) • Introduce new products or make changes to existing product lines • Improve quality and consistency of your product by executing a repeatable process • Simplify data collection and batch reporting for compliance, process improvement, and track & trace FactoryTalk eProcedure® (page 4) • Improve productivity by seamlessly integrating manual work instructions into the automatic process • Link to electronic production documents such as operating procedures, material safety data sheets, and equipment maintenance manuals FactoryTalk Batch Material Manager (page 5) • Reduce system engineering costs by integrating real-time material management capabilities into your batch process • Simplify plant-level material management and tracking of material lots, storage containers, locations, and material properties Additional Features (page 6)

Overview The FactoryTalk Batch Software Suite empowers you to standardize product definitions, improve product quality, simplify product development, speed up system deployment, and reduce implementation cost and risk. FactoryTalk Batch Software Suite provides: • Operators the view to effectively control the process • Production the information to understand what’s happening on the plant floor • Recipe authors an environment to easily build and manage product recipes • Management the information needed to make sound business decisions • Quality the information needed to improve the process and meet compliance requirements • Maintenance the tools required to quickly diagnose problems • System designers the tools to support modular batch automation using industry standards • Engineers the ability to seamlessly connect the software to the control system FactoryTalk Batch Software Suite Version 11 benefits include:

Additional Capabilities (page 7)

• New intelligent recipe features • Improved runtime user control • Expanded data collection and reporting • Enhanced material management capability

FactoryTalk Batch Recipe Management and Procedural Control FactoryTalk Batch provides efficient, predictable batch processing, consistency between batches, and generation of event information during batch runs. FactoryTalk Batch development tools enable you to define equipment configurations and then build product recipes against that defined equipment. These activities simplify the development of each batch control system. FactoryTalk Batch brings all facets of batch automation and process management together, providing the most comprehensive batch management software available.

FactoryTalk Batch Recipe Editor Define Your Product Recipes In FactoryTalk Batch, the Batch Recipe Editor is used to help you build recipes that define the sequence of equipment actions in a batch process. The Batch Recipe Editor provides a simple way to configure, organize and store recipe information according to the ISA88.01 procedural model. Recipes are built hierarchically and consist of procedures, unit procedures, operations and phases. Recipes also include descriptive information, formula information, equipment requirements, and the procedures used to make the batch.

FactoryTalk Batch Equipment Editor Configure Your Equipment FactoryTalk Batch leverages the ISA88.01 physical model hierarchy to configure the physical equipment of your batching operations. Using the graphical interface in the Batch Equipment Editor, you use templates to create and maintain information about your process equipment. Once you’ve defined the equipment, information is available to all other FactoryTalk Batch components.

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FactoryTalk Batch View View and Control Your Batch Process The standard human interface to our system is the Batch View. Through the Batch View options, you initiate recipes, control batches and access all FactoryTalk information. You can command and monitor batches from the Batch List window, a table view, or from the Sequential Function Charts of the selected batch. The Batch View can be used stand-alone or the individual Batch View components can be added directly into container applications, such as HMIs, web browsers or Visual Basic programs.

FactoryTalk Batch Server Manage Your Batch Operations The Batch Server is the engine that runs FactoryTalk Batch. It allocates resources, supports system failure recovery, and provides communication functions. It gathers and stores production information into the Batch Event Journal for reporting and archiving. The Batch Server also supports redundant storage. During runtime, the Batch Server is continuously journaling all actions to one or multiple disk drives so that you can fully recover data in the event of control system failure for system redundancy.

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FactoryTalk eProcedure Process Management for Manual Operations FactoryTalk eProcedure automates manual procedures using an interactive, web-based interface to sequence and document your manufacturing operations. eProcedure provides the consistency of automated controls in manual operations. Use eProcedure to guide operators through manual activity or add links to production documents such as operating procedures, material safety data sheets, and equipment maintenance manuals.

Leverage an Interactive Web-Based Design FactoryTalk eProcedure allows you to interact with batches from remote computers using Microsoft® Internet Explorer. With eProcedure, you no longer need to write processing information on a piece of paper for submission. You can enter the data directly into your workstation. The data is directly stored in an electronic batch record which can be downloaded into your ODBC-compliant database for tracking.

Integrate Manual Work Instructions into Your Automated Process FactoryTalk eProcedure can be implemented in a completely manual manufacturing facility or in a partially automated facility by using all manual phases or a combination of manual and automated phases within a single recipe. Regardless of the state of automation, the implementation process is the same. With eProcedure, your paper-based operating procedures are no longer required!

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FactoryTalk Batch Material Manager Material Management for Batch Operations FactoryTalk Batch Material Manager brings just-in-time material management to batch execution systems, allowing more effective management of materials and recipes. FactoryTalk Batch Material Manager provides plant-level material management and tracking, and integrates with company-wide inventory management systems. It complements ERP-level resource management by collecting the detailed material and equipment tracking information needed for optimizing your supply chain and e-business fulfillment.

FactoryTalk Batch Material Manager Define your Inventory The Material Editor provides an interface to help you define material definitions, which consist of material, lot, sublot, container, and storage location data. During a batch run, information about available containers can be presented to the operator for selection decisions. After a batch is run, quantities consumed or distributed are updated in the material database for use in inventory tracking.

Integrate Material Management into Your Product Definitions Material-based recipes allow you to define recipes in terms of materials used, not just by plant equipment. A material-based recipe uses material-enabled phases, which are configured in the Equipment Editor and stored in the area model. Material-enabled phases support the specification of a material as a means to find appropriate equipment and select that equipment in a recipe.

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Software Suite: Additional Features PhaseManager™ Preferred Integration with Logix Controllers FactoryTalk Batch integrates with Logix PhaseManager, which embeds the ISA88 phase state model directly in a Logix-based controller. PhaseManager provides a structure to streamline the creation and implementation of phase logic. The Phase Logic Interface is now embedded directly in the controller.

XML Support Extend Your Connectivity The Batch Equipment Editor can read, import, and export XML area model files, following the S88-S95 schemes. This makes it possible for the Batch Equipment Editor to be integrated into third-party editors or editing procedures. The area model schema includes signature templates and verification policies. The Batch Recipe Editor can read and write XML master recipes and the Batch Server can read XML master recipes.

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FactoryTalk Batch Simulator Test Your Recipes

FactoryTalk Batch Archiver Send Data to a Database

You can test recipes against plant configurations without running them in the plant using the Batch Simulator. You can configure Batch Simulator to match a specific project or application. During simulation runtime, you can modify phases, change phase states, and cut-over one phase at a time, speeding the debugging process.

The Batch Archiver option collects data from your electronic event journals and stores it in an OBDC-compliant relational database, such as SQL Server or Oracle®. Each batch is recorded in a separate file that contains a complete record of all activity for both manual and automated workflow, including time stamps, batch IDs, user names, computer names and process cells.

Security and Auditing Secure Your Environment The security capabilities within FactoryTalk Batch were designed with input from major pharmaceutical clients and now tightly integrate with FactoryTalk Security and aspects of the FactoryTalk Services Platform. The security levels can be customized to meet the most demanding requirements, such as the U.S. Food and Drug administration (FDA) Good Manufacturing Practice (GMP) regulations. Auditing provides you with a detailed audit trail of user changes to the area model and recipe data made from the Batch Equipment and Recipe Editors. These audit messages are forwarded to FactoryTalk Diagnostics and FactoryTalk Audit, and aspects of the FactoryTalk Services Platform. FactoryTalk AssetCentre diagnostic destination is also supported.

PC-Based Phases Integrate Higher Level Programming Languages FactoryTalk Batch allows for Visual Basic or Visual C++ PC-based phases that communicate with the Batch server without the use of a process-connected device. PC-based phases can be used for a variety of tasks, such as operator prompts, timer, and calculations. By using PC-based phases instead of phase logic, you can decrease the memory required within your process-connected devices.

Additional Batch Management Capabilities Batch Reporting With nine pre-configured web-based batch reports that leverage data already being collected by FactoryTalk Batch, this reporting solution can solve your most common batch reporting needs including electronic batch records (EBR), track & trace genealogy, and production exceptions. Since these reports are built on open Microsoft Reporting Services technology, you can create additional custom batch reports quickly and easily from these existing open source templates. Batch Reporting includes the following templates: • Batch Reports - Batch Listing, Batch Summary, Batch Detail • Material Reports - Material Usage, Forward Tracking, Backward Tracing • Analysis Reports – Batch Execution, Duration Comparison, Batch Exceptions

Integrated Batch Visualization Seamlessly integrate batch control into the operator interface with this solution which offers configurable, pre-engineered FactoryTalk View graphics with embedded FactoryTalk Batch View components. Since all graphics are built using standard product features, you can quickly and easily create custom views from existing screens. Integrated Batch Visualization includes: • Full Screen Graphics - Overview Batch Screen, Line/Unit Batch Screen, eProcedure Batch Screens • Pop-up Graphics - Instructions, Signatures, Prompts, Add Batch • Documented Batch API code - Batch List, Units List, Recipe List, Add Batch, Batch Commands

Batch System Status The Batch System Status application provides you with a new way to take advantage of key information from the FactoryTalk Batch system. This Microsoft Windows Service collects batch system details from the batch server, organizes that data into two useful groupings (batch status, unit status), and downloads the status information to the controllers. The information can be used for process control decisions in code or displayed to the operator through predefined FactoryTalk View HMI objects. Key status data includes: • Batch List Summaries, Recipe Header Detail, Active Mode/State Status of Each Unit’s Batch. • Batch and/or Unit Indication for Active Instructions, Prompts, Signatures, & Failures 7

For More Information To learn more on Rockwell Automation process solutions, the FactoryTalk Batch Software Suite, and other add-on capabilities visit these websites: www.rockwellautomation.com/process http://rockwellautomation.custhelp.com/ Search on answer ID 62366

Rockwell Automation, FactoryTalk, eProcedure, Allen-Bradley, and PhaseManager are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication FTALK-PP002B-EN-P – June 2010

Supersedes Publication FTALK-PP02A-EN-P – June 2007

Copyright © 2010 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.