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Tieghi Anipla 20 04 2010 Come Possiamo Essere Sicuri Che Tutti Seguano Le Procedure
The document discusses the importance of workflow automation in industrial production, emphasizing how systematic processes and digital solutions enhance efficiency and quality control. It outlines various production levels, from basic scheduling to complex task management, and highlights the integration of different systems such as ERP and manufacturing intelligence. Examples of workflow applications in industries like pharmaceuticals, chemicals, and food processing illustrate how digital procedures can streamline operations and improve compliance.
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Tieghi Anipla 20 04 2010 Come Possiamo Essere Sicuri Che Tutti Seguano Le Procedure
- 1. Workflow, ovvero“Come possiamoesseresicurichetuttiseguano(correttamente) le procedure di produzione?”Enzo M. Tieghietieghi@servitecno.it
- 2. All’inizio….Le prime istruzionidaseguire…(manualeoperatore?) InfrastructureFinanceMedia
- 3. …aigiorninostriQuanteinformazioni (e quanta…confusione?)InfrastructureFinanceMedia
- 4. Quantiprocessicisono in Azienda?In quantisonocoinvolte “persone”? Schedulazione/LancioProduzioneAnalisi/QualitàProdottofinitoValutazioneScarti di produzioneControlloQualitàmateria primaConfezionamentoProdottofinitoPuliziamacchineRicevimentoMaterialeStoccaggiomaterialeQuarantenaProdottiControlloRi-lavorazioniCalibrazioneTaraturaDeviazioniProdottiAzioniCorrettiveSetup MacchineGestioneAllarmiDistribuzioneOrdini in ProduzioneMetal Detector CheckImpostazione target, set-point
- 5. Business Process &Work Process ManagementnelleAziendeIndustriali (secondoilmodello di ISA s95)Business Planning & LogisticsPlant Production Scheduling,Operational Management, etcManufacturing Operations ManagementDispatching Production, Detailed ProductionScheduling, Quality Assurance, ...BatchControlDiscreteControlContinuousControlLevel 44 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels. Time Frame Months, weeks, days, shifts ERP <-> Production SystemProduction Order CompletedBackflush InventoryMaintenance ExecutionActual Production Order StatusBPMLevel 3Workflow3 - Workflow / recipe control, stepping the process through states to produce the desired end products. Maintaining records and optimizing the production process. Time Frame Shifts, hours, minutes, secondsProduction Order DispatchingEngineering and Spec ChangesCorrective ActionMaintenanceTask ManagementMuro del Real-Time (firewall?)WPMLevel 2Digitized Work InstructionsTask ExecutionStation-Level ControlManual Data Entry2 - Monitoring, supervisory control and automated control of the production processLevel 11 - Sensing the production process, manipulating the production processAlarm Analysis/ and ActionMfg Intelligence DataCondition Monitoring
- 6. Data Models –ISA s95 ComplianceEquipment Model
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- 16. Work OrderProviamo adimmaginare se…Il nostromiglioreoperatore:Fosse al lavoro 24h su 24 / 7gg su 7 / 365 ggall’anno
- 17. Prendessesempre le decisionigiusteseguendole procedure di produzioneapprovate dal QA e secondogli standard definiti
- 18. Si incaricasse diprodurresemprerispettandoi tempi, aicostipreventivati e secondoilmigliorlivello di Qualitàraggiungibile
- 19. Come?Cos’è un Workflow?“L’automazione/digitalizzazionedi un processo… duranteilqualeun’informazione o un task simuovonoda un partecipante al successivo per far accadereun’azione…secondounaserie di regole.”
- 20. Esempio di Procedurae WorkFlowUn controllo di qualità, manualeFare un prelievo del materiale per il QC
- 21. DefinireilWorkFlow per “Digitalizzare”la procedura di produzione3 PassiDefiniregraficamente la logica per l’esecuzionedeipassaggi del processo e deglieventi/trigger del workflow
- 22. Includere le interazionimanualiedautomatichetraoperatori,equipment e macchine
- 23. Il Wokflow èpronto per l’esecuzionesecondoquantodefinito e con la raccoltadeidati e documentazioneIl tuttosenzadoverlo “cablare” con il campo (con PLC/SCADA/DCS) e senzaprogrammazione con strumenti e tool IT
- 24. “Orchestriamo” tuttiiprocessi diProduzioneWorkflowProcess BatchDefine Brewery SetupCreate/Modify Site RecipeCreate/Modify Master RecipeCreate BatchCreate/Modify Control RecipeProcess BatchComplete BatchDiamovisibilità al Processo
- 25. Integrazionetra: Industrial Workflow& Process Automation (es. Farma)
- 26. Alcunideipiùcomunicasiaffrontati: Work Instructions-Electronic Work Instructions / SOPs- "Standard Work" for Lean Initiatives – “Error proofing”- Production Set Up- Virtual TrainerQuality- Quality Hold: Non Conformance, Rework and Quarantine - QA Plan & SamplingCorrective Action- Alarm Management and Corrective Action - Exception Management - HACCP Monitoring Procedures - Troubleshooting Trees: Equipment Repair & In-Process Product RepairMiddleware - Production Specification & Recipe Management - Industrial MiddlewareMost PopularMost PopularMost Popular
- 27. Esempio di manutenzionein linea 1SignalFailureCondition monitoringpicks up on failureFaults reported .Require simultaneous action30mnlaterSupervisor escalation SMS/e-mail if no responseFault combination triggers workflow(s)Priority WorkOrder(s) issuedService engineer(s) notifiedinstantly via wireless deviceELLIPSE work planning system notified with feedbackWorkflow Acknowledge & DispatchEngineer guided through requiredactions on wireless deviceWork OrderclosedSupervisor report issued as e-mailSpare parts orderedas requiredData recorded for Auditing& Data analysisELLIPSE work planning system notified of completion
- 28. Esempio di manutenzionein linea 2Flag raised in Historian toinitiate maintenance activityMotor VibrationCondition monitoringpicks up on failureMaintenance Work Ordergenerated in Maximo / SAP PMPriority WorkOrder(s) issuedFault combination triggers workflow(s)30min laterWorkflow Acknowledge & DispatchEngineer(s) notified viawireless deviceSupervisor escalation if no responseWork Order inserted into productionschedule as requiredEngineer guided through requiredactions on wireless deviceWork Orderclosed Supervisor report issued as e-mailMaterial consumption reported& spares ordered as required Data recorded for Auditing& performance analysisAsset Mgt System (Maximo/SAP PM) notified of completion
- 29. EsempioApplicativoAcquedotto (City ofHaverhill)Electronic Standard Operating ProceduresEmergency Response PlanVersion ComplianceAlarm Management
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- 33. MiddlewareEsempioApplicativo:Depurazione/TrattamentoAcqueReflueElectronic Standard OperatingProceduresWet Weather Event ResponseAlarm Management
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- 37. MiddlewareEsempioApplicativo: CPG Prodottiper l’igienepersonaleElectronic Standard Operating Procedures
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- 40. MiddlewareAsempioApplicativo: Life SciencePfizer- CapsugelElectronic Standard Operating Procedures
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- 42. Quality SamplingCollection tooslowLine Change-Over
- 43. Middleware“Capsugel chose ProficyWorkflow because it is an innovative product and essentially can do what no other product on the market can do.”- Rovisys
- 44. EsempioApplicativo: ChemicalSABIC InnovativePlasticsElectronic Standard Operating Procedures
- 45. Lean Production InitiativesWasteIdentificationProcess ImprovementException Management
- 46. MiddlewareEsempioApplicativo: ProduttoreInternazionale diBirreElectronic Standard Operating Procedures
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- 55. MiddlewareIl contestodelleapplicazioniindustrialiWorkFlow &SOASOAinc. 3rd party
- 56. SOA: Service OrientedArchitecture3rd PartyApplicationsHMIHistorianWorkflow MESProficy SOAiFIXTroubleshooterCimplicityMaint. GatewayPlant ApplicationsHistorianChange MgtDatamartWorkflowOpen EnterpriseEventsBatch ExecutionPortalSchedulerData/Equip. ModelsTrackerModulesServices
- 57. SOA: Service OrientedArchitecture
- 58. WorkFlow & ProcedureOperativeetieghi@servitecno.it
Editor's Notes
- #3 And who we are is……a global infrastructure, finance, and media company taking on the world’s toughest challenges.
- #4 And who we are is……a global infrastructure, finance, and media company taking on the world’s toughest challenges.
- #5 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.
- #10 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.