Batch Recipe Synchronization via Runtime Version Switching
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Solution Overview
Problem
Existing batch execution technologies are inflexible and unable to respond effectively to sudden changes in recipes during ongoing batch processes, particularly in complex modern batch process plants, which is a challenge for maintaining product quality and compliance with regulatory requirements like the FDA's Process Analytic Technology initiative.
Innovation Solution
A batch execution environment that allows users to synchronize a running batch with a new version of a recipe by interrupting and resuming the batch with the updated version, using a batch subsystem that automatically identifies differences and can perform resynchronization on demand or automatically, with options for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a batch execution environment uses traditional fixed recipe versions, then system stability is maintained, but adaptability to recipe changes deteriorates
Solution Approach 1:
The batch execution environment transitions from static recipe version handling to dynamic version management. The system continuously monitors for new recipe versions and enables runtime switching between versions, allowing the batch process to adapt dynamically to updated recipes while maintaining execution stability through controlled transition mechanisms.
Solution Approach 2:
A recipe version management intermediary layer is introduced between the recipe storage and batch execution components. This intermediary monitors recipe versions, detects updates, and manages the transition process, allowing recipe changes to be propagated to running batches without directly disrupting the execution engine's stability.
2Manufacturing precision
If recipe changes are implemented during ongoing batch processes, then product quality compliance is improved, but process complexity increases
Solution Approach 1:
The system performs preliminary actions by pre-monitoring and detecting new recipe versions before they are applied to running batches. The batch execution environment proactively identifies available updates and prepares for controlled implementation, ensuring quality compliance through advance verification before actual recipe changes occur during batch execution.
Solution Approach 2:
A feedback mechanism is established where the batch execution environment continuously monitors for recipe version updates and provides status information about synchronization state. This feedback loop allows the system to track whether running batches are using updated recipes, enabling quality compliance verification while managing complexity through automated status tracking.
3Measurement precision
If manual intervention is required for recipe synchronization, then control precision is improved, but response time deteriorates
Solution Approach 1:
The batch execution environment implements self-service capabilities by automatically detecting new recipe versions, identifying affected running batches, and initiating synchronization processes without requiring manual intervention. The system autonomously manages the entire recipe update workflow, from detection to implementation, while still allowing operator oversight and control when needed.
Solution Approach 2:
The system applies partial action by selectively synchronizing only those batch processes that are affected by recipe changes, rather than forcing updates to all batches. This targeted approach reduces unnecessary interruptions and response time while maintaining control precision by applying updates only where needed based on actual recipe version mismatches.
Data Source
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AI summary
The present invention discloses a method of executing a plurality of batch processes within a process plant according to a product recipe, wherein the product recipe specifies a plurality of actions and a plurality of parameters, the method comprising: receiving a first version of the product recipe; applying the first version of the product recipe to a first batch runner and a second batch runner, wherein each of the first batch runner and the second batch runner controls the execution of the product recipe using respective process control equipment; initiating a respective batch run consistent with the first version of the product recipe at each of the first batch runner and the second batch runner; receiving a second version of the product recipe, wherein the second version of the product recipe differs from the first version of the product recipe in at least one of the plurality of actions or the plurality of parameters; suspending the execution of the batch run at the first batch runner; applying the second version of the recipe to the first batch runner prior to the first runner completing the execution of the first version of the recipe; and resuming the execution of the batch run at the first batch runner according to the second version of the recipe.