MES Parameter Generation for Batch Production Security

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Solution Overview

Problem

In modern industrial production processes, the implementation of process control parameters for batch production is inefficient due to security restrictions and communication limitations between different layers of the enterprise control system, often requiring work-around solutions that compromise accuracy and efficiency.

Innovation Solution

A computer-implemented method and manufacturing execution system (MES) that receives a product recipe from an ERP system, generates a parameter set based on a product template, and implements it into the process control system, ensuring accurate and efficient communication while adhering to security restrictions, and allowing for the reuse of existing parameter settings for similar products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If communication between different layers of the enterprise control system is restricted for security purposes, then system security is improved, but the efficiency and accuracy of implementing process control parameters deteriorates

Engineering Contradiction:
Improvesystem securityVSAvoidefficiency of implementing process control parameters
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent introduces a manufacturing execution system (MES) as an intermediary layer between the enterprise resource planning (ERP) system and the process control system. The MES receives product recipes from the ERP system, generates appropriate parameter sets based on product templates, and implements them into the process control system. This intermediary approach maintains security restrictions between ERP and process control layers while enabling efficient and accurate parameter implementation through the MES, thus resolving the contradiction between system security and implementation efficiency.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Productivity

If work-around solutions are used to bypass security restrictions, then the efficiency of parameter implementation is improved, but the accuracy and reliability of the control system deteriorates

Engineering Contradiction:
Improveefficiency of parameter implementationVSAvoidaccuracy of control parameters
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The MES acts as a legitimate intermediary that operates within the security architecture rather than bypassing it. It receives structured product recipes from ERP, processes them through product templates to generate accurate parameter sets, and implements them into the process control system. This approach maintains both efficiency and accuracy by using a proper interface designed for parameter generation, avoiding the inaccuracies and reliability issues associated with work-around solutions.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The system performs preliminary actions by maintaining product templates that contain pre-defined parameter settings for different products. When a new production order is received, the MES retrieves the appropriate template and generates the parameter set through systematic processing rather than ad-hoc configuration. This preliminary preparation ensures both efficiency (reusable templates) and accuracy (pre-validated parameter structures) without requiring work-around solutions.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If parameter sets are generated from scratch for each production batch, then the accuracy of control parameters is improved, but the time and computational resources required deteriorates

Engineering Contradiction:
Improveaccuracy of control parametersVSAvoidtime for generating parameter sets
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The system uses product templates as reusable copies of parameter configurations for different products. Instead of generating parameter sets from scratch for each production batch, the MES retrieves the appropriate template and generates the specific parameter set by processing the template with batch-specific information from the product recipe. This copying approach maintains accuracy through template validation while significantly reducing the time and computational resources required compared to creating parameters from scratch for every batch.

Inventive Principle:
Principle #26Copying

4Device complexity

If existing parameter settings are reused for similar products, then the computational complexity is reduced, but the manufacturing precision may deteriorate

Engineering Contradiction:
Improvecomputational complexity of parameter generationVSAvoidprecision of control parameters
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The product template approach enables local quality by maintaining general parameter settings that apply to similar products while allowing specific customization for each product and batch. The template provides the common structure and validated parameter relationships, while the MES processes batch-specific information from the product recipe to generate the final parameter set with product-specific adjustments. This ensures both reduced computational complexity (through template reuse) and maintained precision (through localized customization).

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20240004370A1Computer-implemented method for generating control parameters for a process control system
Publication Date: 2024.01.04 BASF SE
  • US20240004370A1 patent drawing
  • US20240004370A1 patent drawing
  • US20240004370A1 patent drawing

AI summary

The invention refers to a method for generating control parameters for a process control system (131, 132) utilized for batch production of a specific product. The method is configured to be used in a MES (120) and comprises a) receiving, by a receiving unit, a product recipe from an ERP system (110), wherein the product recipe comprises information indicative of production requirements for a specific product in a batch production process, b) generating, by a generating unit, a parameter set based on the product recipe, wherein the parameter set is configured to be implemented in the process control system (131, 132), and c) implementing, by an implementing unit, the generated parameter set into the process control system before starting the production of the specific product.