The Secret Life of S88
‘Cause hey, everyone needs a
another acronym to remember
Russell Czolgosz (Chōl·gŏsh)
MTU ChE class of 1999
Lead Automation and Controls Engineer
Dow Corning Corp
Modified by DWC 1-11-2010
for CM4120
Outline
 Background
 What is ISA and S88?
 Recipe Types
 4-parts of the S88 Model




Physical Model
Process Model
Procedural Control Model
Control Activity Model
 Tying it all together
The Secret Life of S88
New Employee Training, Midland MI
June 11, 2009
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Typical Manufacturing Challenges
Need Predictable Product Quality
 Variation in feedstocks
 Poor control of manufacturing processes
 Human error
 Differences between processing locations
Overcome High Manufacturing Costs
 Low equipment utilization – difficulty in scheduling
 Using old processing/control technologies
 Labor intensive
 High cost of energy
 Poor flow of material and information
Would Like New Markets/ New Products
 Need “Agility” but have a dedicated system
 Rigid design creates long product/process
development times
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Traditional Process Development
1. Design equipment for a specific process/
product
2. Develop procedures to make that product
3. Implement process control to meet the
product requirements and fit the SOP
4. At completion all aspects of the SOP/
product/ equipment/ control are rigid, hardcoded, and fixed
This type of implementation:
Hinders Process Improvement
Prohibits Manufacturing Agility
Prevents Asset Optimization
The goal of S88 is to prevent these roadblocks.
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ISA S88 is...
 ISA – International Society of Automation
 S88 (or ISA 88) Batch Control
Standard
Currently a 4-part standard





Part 1 Models and Terminology (ANSI/ISA-88.01)
Part 2 Data Structures & Guidelines for Languages
(ANSI/ISA-88.00.02)
Part 3 General and Site Recipe Models & Representation
(ANSI/ISA-88.00.03)
Part 4 Batch Production Records (ANSI/ISA-88.00.04)
Part 5 is currently in draft
 SP88 is the Batch Control Standards
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Committee
June 11, 2009
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The Intent of S88:
 Promotes modularity and flexibility
 Emphasizes good practices for design/
operation
 Provides a common concepts, framework,
models, and terminology
 Improve efficiency/ control of mfg. plants
(batch, semi-continuous, and continuous)
It is a guideline, NOT a compliance standard
The Secret Life of S88
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S88 – Must be Interpreted!
 S88 defines general practices



Written to apply to the entire processing industry
Makes suggestions and provides examples
Does not list requirements
 Suggests standardized


modular design concepts
Reusable design components
Similar to object-oriented computer programming
The Secret Life of S88
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Benefits of an S88 Solution?
1. Modularity allows for easier replication and
2.
3.
4.
5.
better ROI
Design concepts make validation easier
S88-aware solutions help track product and
process data
Gathering requirements from customers/
conveying requirements to vendors is easier
Provides guidelines on how to recover from
abnormal events
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Spirit of S88
 Not just a standard for software, equipment, or
procedures

A new way of thinking – a design philosophy
 Understanding S88 will help you design better
processes and manufacture better products

Isolates equipment from recipes
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Improved Batch Processing
Throughput







Cost
Reduced batch cycle
time
Increased production
rate
Faster changeover
More scheduled recipes
Reduced downtime
Faster process
development
Quicker product
launches
The Secret Life of S88


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
Reduced raw material
loss
Improved batch
consistency
Better equipment
utilization
Less time to add/modify
recipes
Lower engineering cost
Lower data capture cost
Better data availability
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June 11, 2009
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Steps in Applying S88
1. Learn the terminology
2. Break the process down into appropriate
3.
4.
5.
6.
components
Identify the steps necessary to produce the
product
Identify recipe parameters
Tie the recipe to the procedures
Map the procedure to the processing
equipment
The Secret Life of S88
New Employee Training, Midland MI
June 11, 2009
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S88
Recipe Types
What we want to make, what equipment we
need, and how we want to do it
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4 Recipe Types
General Recipe
May be
transformed into
Site Recipe
May be
transformed into
Master Recipe
May be
transformed into
Control Recipe
Ref. S88.01 Fig.8 – Recipe types
The Secret Life of S88
1. General Recipe
 Enterprise-wide
 Includes product-specific processing
information
2. Site Recipe
 Specific to a site
 Includes site-specific information
(language, raw materials, on-site
limitations, etc.)
3. Master Recipe
 Targeted to a specific cell
 Starting w/ a Site Recipe, is adapted to
Process Cell-specific equipment
4. Control Recipe
 Consists of a Master Recipe plus Batch
ID, batch size, etc.
 Forever tied to a particular batch and is
specific to that batch – permits product
tracking
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Recipe Definition
 A recipe holds the
data that uniquely identifies
the components of a specific product




Ingredients to use
Quantity of ingredients
Equipment requirements
The order in which tasks are performed
 Recipes
do not contain scheduling or
equipment control information
The Secret Life of S88
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Applying S88 – 4 Models Defined
1. Process Model
2. Physical Model
3. Procedural Control Model
4. Control Activity Model
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S88
The Process Model
Describes the hierarchical ordering of process
functionality needed to produce a batch.
Is not equipment specific – very conceptual.
Used to develop the recipe procedures section in
the General and Site Recipes (high-level recipes).
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Process Model
General and Site Recipe
procedures will be based
on the “Process Model”
Process
Make PDMS
Consists of an
ordered set of
Process Stage
Polymerize
Remove Low Boilers
Cool Product
Consists of an
ordered set of
Process Operation
Prepare Reactor
Charge
React
Consists of an
ordered set of
Process Action
The Secret Life of S88
Add req’d 245 Fluid
Add req’d Endblocker
Heat to 140 C
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S88
The Physical Model
The equipment used to perform the process.
Defines the hierarchy of the equipment.
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Physical Model
Subdivision of the corporation’s PHYSICAL ASSETS organized in a hierarchy of equipment that
consists of several integrated levels
MTU
Houghton
Enterprise
Process
Cell
Site
Unit
Chem Sci
Building
Area
Equipment
Module
PSCC
Consists of all the
production and supporting
equip necessary to make a
batch
A major piece of
equipment within a process
PDMS Reactor cell that performs a
Unit
specific task
Solvent
Recovery
Unit
Agitator
Temp
Feed
Discharge
Grouping of equipment
& control modules that
together perform a
minor task
Basic discrete and analog
Control
Module
The Secret Life of S88
Agitator
control (output) devices
Controls
Outlet valve
Temp Controller
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An Example Process Cell
Process
Cell
Material Selection
Material
Charging
FT
Mix
Pressure
Control
M
Unit
Temperature
Control
TT
PT
Discharge
and
Recirc
Equipment
Module
Pump
FT
Control
Module
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Process
Cell
Defining a Unit
Unit
Equipment
Module
Control
Module
 Batching cannot occur without units



Batching occurs in units
Units perform one or more major processing activities
A unit is used on only one batch at a time
 A Unit


runs a recipe
Combine ingredients, or perform a reaction
Adds value to your product or intermediate
 Units function independently of each other
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Examples of Units:
Is a
Unit
Mix-making batch tank
Pasteurizer
Reactor
Pump
Ingredient storage tank
Washing machine
Kitchen blender
Refrigerator
Dishwasher
The Secret Life of S88
Is Not
a Unit
4
4
4
4
4
4
4
4
4
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Process
Cell
Equipment Modules
Unit
Equipment
Module
 Equipment modules group devices for performing one or
Control
Module
more specific minor processing activities
 Equipment modules run portion(s) of a recipe
FT
Material Charging
Equipment Module
The Secret Life of S88
Mix
M
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Process
Cell
Control Modules
Unit
Equipment
Module
Control
Module
“connect” software to the process through
sensors and actuators
 Control modules
 Act as a single entity from a control standpoint
 Carry out Basic Control – they
control
do not contain procedural
Material
Selection
Temperature TT
Control
The Secret Life of S88
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Physical Model is Collapsible
Process
Cell
Unit
Equipment
Module
Although a process cell must contain at
least one unit:
 A control module does not have to be
part of an equipment module to be part
of a unit
 A unit can “own” control modules directly
Control
Module
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S88
The Procedural Control Model
Sequence of steps necessary to produce a
batch.
Defines the sequential control that enables
equipment to perform the process task.
Used to develop the Recipe Procedures
section of the Master Recipe
The specific control setpoints, quantities,
controller modes, etc. required to make a
defined quantity of a certain product
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Procedural Control Model
Defines the process strategy for making a batch
within a process cell
-A hierarchy of the actions that are performed to
complete a batch
Defines the actions that are performed on a Unit
-Consists of an ordered set of Operations that
control the functions of the unit
Defines an ordered set of phases that are arranged
to perform a particular function within a unit
-One or more operations could occur
simultaneously
Defines a simple action or command to set or
change the state of an Equipment Module
-Can be subdivided into steps and transitions
The Secret Life of S88
Procedure
Unit
Procedure
Operation
Phase
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Make PDMS
Polymerize
Remove Low Boilers
Cool Product
Prepare Reactor
Add Ingredients
Heat
Add 245
Add Endblocker
June 11, 2009
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Procedural Control Model Example
Procedure
Make
Toothpaste
Unit
Procedures
Make Paste
Make Gel
Swirl
Operations
Prepare
Tank
Add
Ingredients
React
Add Water
Add Fillers
Phases
The Secret Life of S88
Phases are the workhorses.
Other levels simply group,
organize, and direct phases.
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Add NaF
June 11, 2009
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The Automation Specification:
Physical Model
Enterprise
A document that describes
how Equipment Modules
are related to a Unit and
how the Phase(s) control
each Equipment Module
Site
Procedural
Control
Model
Procedure
Area
Process Cell
Unit Procedure
Unit
Operation
Equipment
Module
Control
Module
The Secret Life of S88
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Phase
June 11, 2009
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S88 Models Tie Together thru
Mapping
Relates the procedural control model to the
physical model to provide the processing
described in the process model
Involves MAPPING of Procedural Elements into
Physical Entities
The Secret Life of S88
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S88 – Model Relationships
Procedural
Control Model
Procedure
Unit Procedure
Physical Model
Combined
With a
+
Process Cell
Unit(s)
+
Operation(s)
Unit(s)
+
Phase(s)
Phase(s)
Process Model
Provides process
functionality
to carry out a…
Process
Provides the
functionality to
carry out a…
Process Stage
=
=
Unit(s)
+
Equipment
Module(s)
=
Process Operation
Process Action
Process Action
Ref. S88.01 Fig.7 – Procedural control/equipment mapping to achieve process functionality
The Secret Life of S88
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Separate Models Add Flexibility
Separation of Recipe, Procedures, Equipment/
Basic Control into separate models:
 Each component is maintained as an entity
 Changes in the Recipe do not necessarily require
changes to the Phase Logic
 Changes to the Phase Logic do not necessarily
require changes to the Recipe
 Changes to physical equipment do not
necessarily require changes to the other models
The Secret Life of S88
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Summarizing the 1st Three Models
Corporate sends a General Recipe to my Site
 Convert General Recipe to a Site Recipe then
 Convert Site Recipe to a Master Recipe, for each
suitable cell, complete with setpoints, timing,
quantities, tolerances, etc.
When we make a Batch, the Master Recipe gets
transformed into a Control Recipe
 allocate specific equipment
 create a batch identifier
 make the product, record all processing parameters
 Control Recipe forever tied to that batch of product
The Secret Life of S88
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Summarizing the 1st Three Models
In our plant, we define:
 Physical Model (what Units and Equipment
Modules we have and the Basic Control that
operates each)
 Procedural Control Model (all the Phases that each
Equipment Module can be in, what each Phase
accomplishes, and the sequence of operations)
Mapping the Physical Model onto the Procedural
Control Model produces the functionality
described in the Process Model
Process Model describes what Process Actions will
occur in each Phase of the process
The Secret Life of S88
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Recipe Header
Original Nestlé Toll House Chocolate Chip Cookies
Makes about 5 dozen cookies
Batch Size
Batch of Cookies!
Control Recipe
Ingredients:
2 1/4 cups all-purpose flour
1 teaspoon baking soda
Master Recipe
1 teaspoon salt
1 cup (2 sticks) butter, softened
Formula 3/4 cup granulated sugar
3/4 cup packed brown sugar
Inputs
1 teaspoon vanilla extract
2 large eggs
2 cups (12-ounce package) NESTLÉ® TOLL HOUSE® Semi-Sweet Chocolate Morsels
1 cup chopped nuts
O
p
e
r
a
t
i
o
n
s
Directions:
Procedure
PREHEAT oven to 375° F.
Recipe Parameters
COMBINE flour, baking soda and salt in small bowl.
Phases
Beat butter, granulated sugar, brown sugar and vanilla extract in large mixer bowl until creamy.
Add eggs one at a time, beating well after each addition.
Transition Expression
Gradually beat in flour mixture. Stir in morsels and nuts. Drop by rounded tablespoon onto ungreased
baking sheets.
BAKE for 9 to 11 minutes or until golden brown. Cool on baking sheets for 2 minutes; remove to wire
racks to cool completely.
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S88
The Control Activity Model
The 4th Model
“Cactus Model”
Shows relationships between control activities
Describes flow of information throughout the
enterprise
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Control Activity Model
Master
Recipe
Recipe
Management
Master
Recipe
Batch
Production Schedule
Planning and
Scheduling
Batch Schedule
Master
Recipe
Production
Information
Management
Batch Progress
Process Batch and Process
Management Cell Information
Unit Recipes and Commands
Batch Status
Unit
Supervision
Commands
Batch and Unit
Information
Statuses
Process
Data
Process
Control
Commands
Statuses
Below this line is outside S88 Scope
Personnel and
Environmental
Protection
The Secret Life of S88
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Overall Value of S88
 Permits easy product customization

Color, level of impurities, packaging, viscosity, composition,
etc.
 Facilitates rapid product change-over
 Helps identify suitable assets at different sites
 Allows for easy recipe conversion into local
languages
Remember: S88 is only one element in a system of
manufacturing
The Secret Life of S88
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References
 Applying S88 Batch Control from a User’s
Perspective, Jim Parshall and Larry Lamb, ISA,
Research Triangle Park, NC, 2000.
 ISA S88.01-1995 (R2006) Batch Control Part
1: Models and Terminology, ISA, Research
Triangle Park, NC, 2006.
 World Batch Foundation, www.wbf.org
 International Society of Automation,
www.isa.org
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