6 - Batch manufacturing basics

Abstract

This chapter presents the basics of batch manufacturing and introduces various techniques such as batch numbering, tracking, and reporting. One of the main objectives of batch process automation is to manufacture a batch in optimum (minimum) time and to maximize the capacity utilization of the batch manufacturing facility. Investments in batch process automation can be justified by the returns resulting from the improvements in recipe scheduling that are easy to quantify. Various planning and scheduling techniques employing fairly simple to very complex algorithms are used for optimization of batch manufacturing processes in the industry. The chapter presents the concepts of batch planning and scheduling. Every plant executes based on a production schedule. The schedule may come from a planning entity somewhere in the company and it is usually produced on a regular schedule such as monthly, weekly, or daily. The schedule may be produced in different forms—such as a computer printout and a spreadsheet file. It can also be electronically downloaded to the batch execution system. The production schedule received from planning typically holds only addresses of the production of products, and not the other collateral production procedures that must be executed—such as the cleaning procedures that are commonly required in the food and pharmaceutical industries.