Task Execution Assistance System for Batch Production Control
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Solution Overview
Problem
Current batch production systems face challenges in integrating the manufacturing execution system (MES) with real-time batch production control systems, leading to inefficiencies and a lack of overall life cycle management in production control systems.
Innovation Solution
A system comprising an enterprise management system, manufacturing execution system (MES), and task execution assistance (TEA) system, interfaced with a production control system, utilizing Object Linking and Embedding for Process Control (OPC) interfaces to manage batch production requests and commands, enabling real-time monitoring and execution of batch processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ERP-MES integration is realized, then enterprise application coordination is improved, but MES to real-time batch production control system integration remains challenging
Solution Approach 1:
The patent introduces a Batch Control System as an intermediary layer between the MES and the real-time production control system. This Batch Control System receives batch production requests from MES, manages the batch lifecycle, and coordinates with the real-time control system through standardized interfaces, thereby resolving the integration challenge while maintaining reliability.
2Productivity
If batch production control system manages overall life cycle in real time, then productivity and transparency are improved, but system complexity increases
Solution Approach 1:
The patent segments the batch production control into distinct functional modules: batch request management, batch command generation, batch execution monitoring, and batch completion handling. Each module performs a specific function in the batch lifecycle, enabling real-time management while keeping individual components manageable and reducing overall system complexity.
Solution Approach 2:
The Batch Control System implements dynamic batch command generation and execution monitoring that adapts to real-time production conditions. The system dynamically adjusts batch processing based on actual plant operations and distributed control system status, enabling improved productivity through flexible real-time control without requiring overly complex static configurations.
3Loss of time
If coordination between MES and production control system is enhanced, then turnaround time is reduced, but integration difficulty increases
Solution Approach 1:
The Batch Control System performs preliminary actions by pre-generating batch commands and preparing batch execution plans before actual production starts. The system receives batch production requests from MES and proactively creates the necessary control instructions and coordination protocols, reducing turnaround time by eliminating setup delays while managing integration complexity through structured preliminary processing.
Data Source
AI summary
A system and method for managing life cycle of a batch in a production control system in real time. The system comprises of an enterprise management system, manufacturing execution system (MES), task execution assistance (TEA) system and a production control system. The TEA system is interfaced between the MES and the production control system for executing the production request. The batch production request generated by the enterprise management system is received by the MES wherein the MES forwards the batch production request to the TEA system. The TEA system obtains information required to execute the batch production request from the production control system. Upon obtaining the information the TEA system instructs an operator to create the batch in the production control system. The production control system confirms the creation of the batch and updates real time status of the batch to the TEA system.