General Recipe Generation from Master Recipes
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Solution Overview
Problem
The existing standards for batch process recipes, such as ANSI/ISA-S88 and IEC 61512-01, lack a method for automated conversion of master recipes to general recipes, making it difficult to adapt recipes between different sites and scales, and requiring manual, equipment-specific creation of master recipes.
Innovation Solution
A method and device that convert master recipes to general recipes by identifying and removing site-specific support segments, calculating general process property values, and adjusting scheduling relationships to create a recipe independent of equipment, consumables, and personnel, allowing for site and scale flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual creation of master recipes is performed for each site and equipment configuration, then recipe specificity and reliability are improved, but time consumption and operational complexity increase significantly
Solution Approach 1:
The system creates master recipes by copying and adapting a generic recipe template rather than creating each recipe from scratch. The conversion process automatically copies process elements, parameters, and structures from the generic recipe and modifies them to fit site-specific requirements, dramatically reducing the time needed while maintaining reliability through systematic adaptation
Solution Approach 2:
A generic recipe is prepared in advance with all necessary process elements, parameters, and structures defined in a standardized format. This preliminary creation of a reusable template allows subsequent site-specific recipes to be generated quickly through automated conversion, eliminating the need for manual creation each time
2Manufacturing precision
If manual creation of master recipes is performed for each equipment configuration, then equipment-specific accuracy is improved, but device complexity and operational burden increase
Solution Approach 1:
The system copies the structured framework, process logic, and parameter relationships from the generic recipe and automatically adapts them to specific equipment configurations. This automated copying process maintains equipment-specific accuracy while eliminating the operational burden of manual recipe creation for each equipment setup
Solution Approach 2:
A single generic recipe serves multiple functions across different sites and equipment configurations. The conversion system makes this universal recipe adaptable to various specific contexts through automated parameter adjustment and equipment mapping, reducing operational complexity while maintaining precision
3Productivity
If automated conversion from master recipes to general recipes is implemented, then productivity and operational efficiency are improved, but implementation complexity increases
Solution Approach 1:
The automated conversion system copies and transforms recipe data between formats using predefined rules and mappings. This systematic copying approach with automated parameter transformation achieves high productivity while managing implementation complexity through structured data handling and standardized conversion processes
Data Source
AI summary
A method of generating a general recipe for an industrial process that is not site or resource specific to from a master recipe that is site and resource specific, comprises:a) deleting any process elements of the master recipe that are support segments that relate only to resources assigned to the master recipe;b) creating records in the general recipe for any process properties that are designated as not site specific;c) creating records of resource requirements and requirement groups for process elements associated with such resource requirements; andd) determining scheduling relationships for the process elements of the general recipe so generated by:(i) determining which process elements are primary and which are secondary;(ii) determining the processing relationship of other process elements with respect to primary process elements; and(iii) storing data defining whether the processing relationships are general or site specific.