OpreX Batch Solution

Scope of OpreX Batch Solution

OpreX Batch Solution integrates the key features of PCS and MES for any batch process plant.
In addition to typical PCS operation, most batch plants require batch management MES functionality for production scheduling, dispatching, recipe management, field operation support, and electronic batch recording.

As indicated in the diagram below, OpreX Batch Solution is aligned with the ISA-95 Enterprise-Control System Integration standard and incorporates all necessary functionalities required by batch processes.

OpreX Batch Solution is aligned with the ISA-88 Batch control standard as well. Reusable modules for contents of procedural control models and physical models are available for efficient implementation.

Value 1: Increase Cost Effectiveness

OpreX Batch Solution increases cost effectiveness by delivering high production quality through a simplified and compressed PCS and MES design process, along with improved MES execution management.

Simplified and Compressed PCS Design and Engineering

OpreX Batch Solution provides essential functions to simplify and shorten the duration of PCS design and engineering, including:

• Reusable standard modules:
  Minimizes development effort and maintains engineering quality for batch process design and recipe creation.
• Discussion tool for design with batch manufacturers:
  Users can design applications and check their functionality, with no programming knowledge required. These and other capabilities simplify creation of documents, such as User Requirement Specifications and Functional Design Specifications.

Simplified and Compressed MES Design and Implementation

Yokogawa cultivates and captures know-how using MES templates. These provide typical MES functions, contributing to shorter time for MES design and implementation. These templates cover typical MES functions: recipe management, order management, inventory management, execution management, field operation support, reporting, and lot tracing—while providing integration with related systems.

MES Execution Management

The Yokogawa MES solution supports improved quality, cost and delivery (QCD) in production by ensuring there is less human error and reduced material loss.

• Standard Operating Procedure (SOP) management:
  Shows SOPs detailing all field operations to ensure defined actions are performed.
• 4M condition display:
  Displays the four most important production elements: huMan (operator), Machine (plant asset), Material (raw material), and Method (production method).
• Field operation navigation and barcode identification:
  Confirms efficient and accurate manual operations.

Value 2: Reduce Time to Market

OpreX Batch Solution helps reduce time to market by facilitating easy recipe changes and simplified plant expansion, along with integrated batch reporting.

Recipes Changes and Plant Expansion

A fundamental concept of OpreX Batch Solution is flexible recipe and formula changes, with a graphical approach based on reusable proven modules to simplify recipe engineering work.

With the proven value of Yokogawa’s PCS engineering environment, plant expansion engineering effort can be dramatically reduced. Thanks to module-based engineering, only I/O information changes or additions are needed for plant expansion, avoiding extensive coding and other significant modifications.

Integrated Batch Reporting

OpreX Batch Solution can record both PCS and field operator manual operations and document each by issuing an integrated batch report. All operations are defined in a single development environment during the engineering phase.

Value 3: Improve Production Quality

OpreX Batch Solution helps improve production quality through three approaches: improve PCS operation, improve field operation, and analyze operational data.

Analyze Operational Data

Yokogawa provides data analytics solutions and services to improve production quality. Using batch manufacturers’ process data, operational data, and process knowledge, Yokogawa can leverage strengths in analytics and measurement/control in a collaborative approach to identify problems and create action plans, improving quality and productivity.