Tieghi Anipla 20 04 2010 Come Possiamo Essere Sicuri Che Tutti Seguano Le Procedure


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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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  • And who we are is……a global infrastructure, finance, and media company taking on the world’s toughest challenges.
  • And who we are is……a global infrastructure, finance, and media company taking on the world’s toughest challenges.
  • There are literally 1000s of work processes within any facility. Can be administrative, production scheduling, quality, materials management, equipment setup, equipment operations, maintenance, shipping and receiving. They can be very specific such as take an in-line quality sample every hour for product x or every 10 minutes for product y. Or deliver complete setup instructions for the equipment and download a recipe to run a batch of product x.With most work processes, people are involved to carry out the steps within the process. This involves knowledge and experience of the work that is to be done and diligence to complete the work correctly.
  • What is a Work Process?Work processes can be defined very broadly. What we are talking about is Industrial or Production Work processes. Some people think of Work Process as Business Processes, and it could be but we are talking about everyday things we do to get the job done. Lets discuss the concept of a work process.This is a SOP or Standard Operating Procedure for taking quality samples. In particular, taking a random finish product sample. This SOP is pretty complex and involves 11 pages! A lot of opportunity for error by the person taking the sample. Everyone makes mistakes and cuts corners, or even forgets how to do things. First challenge is tracking down the SOP, second is making sure you have the latest version. I have been in a plant where I found 6 different versions of the same SOP in a matter of one hour.To complete this work process it will involve 1 person, it could take an hour or so, and will require numerous individual steps. Another thing to note, all the records are kept on a piece of paper. Often times these paper records are misplaced and only have limited value because they cannot be easily shared.
  • Tieghi Anipla 20 04 2010 Come Possiamo Essere Sicuri Che Tutti Seguano Le Procedure

    1. 1. Workflow, <br />ovvero<br />“Come possiamoesseresicurichetuttiseguano (correttamente) le procedure di produzione?”<br />Enzo M. Tieghi<br />etieghi@servitecno.it<br />
    2. 2. All’inizio….<br />Le prime istruzionidaseguire… <br />(manualeoperatore?) <br />Infrastructure<br />Finance<br />Media<br />
    3. 3. …aigiorninostri<br />Quanteinformazioni (e quanta… confusione?)<br />Infrastructure<br />Finance<br />Media<br />
    4. 4. Quantiprocessicisono in Azienda?<br /> In quantisonocoinvolte “persone”? <br />Schedulazione/<br />LancioProduzione<br />Analisi/Qualità<br />Prodottofinito<br />Valutazione<br />Scarti di produzione<br />ControlloQualità<br />materia prima<br />Confezionamento<br />Prodottofinito<br />Pulizia<br />macchine<br />Ricevimento<br />Materiale<br />Stoccaggio<br />materiale<br />Quarantena<br />Prodotti<br />Controllo<br />Ri-lavorazioni<br />Calibrazione<br />Taratura<br />DeviazioniProdotti<br />AzioniCorrettive<br />Setup Macchine<br />GestioneAllarmi<br />DistribuzioneOrdini in Produzione<br />Metal Detector Check<br />Impostazione target, set-point<br />
    5. 5. Business Process & Work Process ManagementnelleAziendeIndustriali (secondoilmodello di ISA s95)<br />Business Planning <br />& Logistics<br />Plant Production Scheduling,<br />Operational Management, etc<br />Manufacturing <br />Operations Management<br />Dispatching Production, Detailed Production<br />Scheduling, Quality Assurance, ...<br />Batch<br />Control<br />Discrete<br />Control<br />Continuous<br />Control<br />Level 4<br />4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels. <br />Time Frame<br /> Months, weeks, days, shifts <br />ERP <-> Production System<br />Production Order Completed<br />Backflush Inventory<br />Maintenance Execution<br />Actual Production Order Status<br />BPM<br />Level 3<br />Workflow<br />3 - Workflow / recipe control, stepping the process through states to produce the desired end products. Maintaining records and optimizing the production process. <br />Time Frame<br /> Shifts, hours, minutes, seconds<br />Production Order Dispatching<br />Engineering and Spec Changes<br />Corrective Action<br />Maintenance<br />Task Management<br />Muro del Real-Time (firewall?)<br />WPM<br />Level 2<br />Digitized Work Instructions<br />Task Execution<br />Station-Level Control<br />Manual Data Entry<br />2 - Monitoring, supervisory control and automated control of the production process<br />Level 1<br />1 - Sensing the production process, manipulating the production process<br />Alarm Analysis/ and Action<br />Mfg Intelligence Data<br />Condition Monitoring<br />
    6. 6. Data Models – ISA s95 Compliance<br /><ul><li>Equipment Model
    7. 7. Personnel Model
    8. 8. Material Model
    9. 9. Product Definition
    10. 10. Product Parameters
    11. 11. Personnel Specifications
    12. 12. Equipment Specifications
    13. 13. Material Specifications
    14. 14. Process Segments
    15. 15. Product Segments
    16. 16. Work Order</li></li></ul><li>Proviamo ad immaginare se…<br />Il nostromiglioreoperatore:<br /><ul><li>Fosse al lavoro 24h su 24 / 7gg su 7 / 365 ggall’anno
    17. 17. Prendessesempre le decisionigiusteseguendo le procedure di produzioneapprovate dal QA e secondogli standard definiti
    18. 18. Si incaricasse di produrresemprerispettandoi tempi, aicostipreventivati e secondoilmigliorlivello di Qualitàraggiungibile
    19. 19. Come?</li></li></ul><li>Cos’è un Workflow?<br />“L’automazione/digitalizzazione di un processo… duranteilqualeun’informazione o un task simuovonoda un partecipante al successivo per far accadereun’azione…secondounaserie di regole.”<br />
    20. 20. Esempio di Procedura e WorkFlow<br />Un controllo di qualità, manuale<br />Fare un prelievo del materiale per il QC<br />
    21. 21. DefinireilWorkFlow per “Digitalizzare” la procedura di produzione<br />3 Passi<br /><ul><li>Definiregraficamente la logica per l’esecuzionedeipassaggi del processo e deglieventi/trigger del workflow
    22. 22. Includere le interazionimanualiedautomatichetraoperatori, equipment e macchine
    23. 23. Il Wokflow è pronto per l’esecuzionesecondoquantodefinito e con la raccoltadeidati e documentazione</li></ul>Il tuttosenzadoverlo “cablare” con il campo (con PLC/SCADA/DCS) e senzaprogrammazione con strumenti e tool IT<br />
    24. 24. “Orchestriamo” tuttiiprocessi di Produzione<br />Workflow<br />Process Batch<br />Define Brewery Setup<br />Create/Modify Site Recipe<br />Create/Modify Master Recipe<br />Create Batch<br />Create/Modify Control Recipe<br />Process Batch<br />Complete Batch<br />Diamovisibilità al <br />Processo<br />
    25. 25. Integrazionetra: Industrial Workflow & Process Automation (es. Farma)<br />
    26. 26. Alcunideipiùcomunicasiaffrontati: <br />Work Instructions<br />- Electronic Work Instructions / SOPs<br />- "Standard Work" for Lean Initiatives – “Error proofing”<br />- Production Set Up<br />- Virtual Trainer<br />Quality<br />- Quality Hold:  Non Conformance, Rework and Quarantine<br /> - QA Plan & Sampling<br />Corrective Action<br />- Alarm Management and Corrective Action<br /> - Exception Management<br /> - HACCP Monitoring Procedures<br /> - Troubleshooting Trees: Equipment Repair & In-Process Product Repair<br />Middleware<br /> - Production Specification & Recipe Management<br /> - Industrial Middleware<br />Most Popular<br />Most Popular<br />Most Popular<br />
    27. 27. Esempio di manutenzione in linea 1<br />Signal<br />Failure<br />Condition monitoring<br />picks up on failure<br />Faults reported .<br />Require simultaneous action<br />30mn<br />later<br />Supervisor escalation <br />SMS/e-mail if no response<br />Fault combination <br />triggers workflow(s)<br />Priority Work<br />Order(s) issued<br />Service engineer(s) notified<br />instantly via wireless device<br />ELLIPSE work planning system <br />notified with feedback<br />Workflow <br />Acknowledge & Dispatch<br />Engineer guided through required<br />actions on wireless device<br />Work Order<br />closed<br />Supervisor report <br />issued as e-mail<br />Spare parts ordered<br />as required<br />Data recorded for Auditing<br />& Data analysis<br />ELLIPSE work planning system <br />notified of completion<br />
    28. 28. Esempio di manutenzione in linea 2<br />Flag raised in Historian to<br />initiate maintenance activity<br />Motor Vibration<br />Condition monitoring<br />picks up on failure<br />Maintenance Work Order<br />generated in Maximo / SAP PM<br />Priority Work<br />Order(s) issued<br />Fault combination <br />triggers workflow(s)<br />30min later<br />Workflow <br />Acknowledge & Dispatch<br />Engineer(s) notified via<br />wireless device<br />Supervisor escalation <br />if no response<br />Work Order inserted into production<br />schedule as required<br />Engineer guided through required<br />actions on wireless device<br />Work Order<br />closed<br /> Supervisor report <br /> issued as e-mail<br />Material consumption reported<br />& spares ordered as required <br />Data recorded for Auditing<br />& performance analysis<br />Asset Mgt System (Maximo/<br />SAP PM) notified of completion<br />
    29. 29. EsempioApplicativoAcquedotto (City of Haverhill)<br /><ul><li>Electronic Standard Operating Procedures</li></ul>Emergency Response Plan<br />Version Compliance<br /><ul><li>Alarm Management
    30. 30. Employee Training
    31. 31. Quality Sampling
    32. 32. Exception Management
    33. 33. Middleware</li></li></ul><li>EsempioApplicativo:Depurazione/TrattamentoAcqueReflue<br /><ul><li>Electronic Standard Operating Procedures</li></ul>Wet Weather Event Response<br /><ul><li>Alarm Management
    34. 34. Employee Training
    35. 35. Quality Sampling
    36. 36. Exception Management
    37. 37. Middleware</li></li></ul><li>EsempioApplicativo: CPG Prodotti per l’igienepersonale<br /><ul><li>Electronic Standard Operating Procedures
    38. 38. Alarm Management
    39. 39. Line Change-Over
    40. 40. Middleware</li></li></ul><li>AsempioApplicativo: Life SciencePfizer - Capsugel<br /><ul><li>Electronic Standard Operating Procedures
    41. 41. Alarm Management
    42. 42. Quality Sampling</li></ul>Collection too slow<br /><ul><li>Line Change-Over
    43. 43. Middleware</li></ul>“Capsugel chose Proficy Workflow because it is an innovative product and essentially can do what no other product on the market can do.”<br />- Rovisys<br />
    44. 44. EsempioApplicativo: ChemicalSABIC Innovative Plastics<br /><ul><li>Electronic Standard Operating Procedures
    45. 45. Lean Production Initiatives</li></ul>Waste Identification<br />Process Improvement<br /><ul><li>Exception Management
    46. 46. Middleware</li></li></ul><li>EsempioApplicativo: ProduttoreInternazionale di Birre<br /><ul><li>Electronic Standard Operating Procedures
    47. 47. Alarm Management
    48. 48. Employee Training
    49. 49. HAACP
    50. 50. Quality Sampling
    51. 51. Line ChangeOver
    52. 52. Recipe Management
    53. 53. Rework Instructions
    54. 54. Exception Management
    55. 55. Middleware</li></li></ul><li>Il contestodelleapplicazioniindustrialiWorkFlow & SOA<br />SOA<br />inc. 3rd party<br />
    56. 56. SOA: Service Oriented Architecture<br />3rd Party<br />Applications<br />HMI<br />Historian<br />Workflow <br />MES<br />Proficy SOA<br />iFIX<br />Troubleshooter<br />Cimplicity<br />Maint. Gateway<br />Plant Applications<br />Historian<br />Change Mgt<br />Datamart<br />Workflow<br />Open Enterprise<br />Events<br />Batch Execution<br />Portal<br />Scheduler<br />Data/Equip. Models<br />Tracker<br />Modules<br />Services<br />
    57. 57. SOA: Service Oriented Architecture<br />
    58. 58. WorkFlow & <br />Procedure Operative<br />etieghi@servitecno.it<br />