Customer Profile
LeaderCompany
in Specialty Hydrocarbons
Name
Food, Cosmetics,
Industrial
Crude Oil Pharma,
Production
Challenge:
ICT Automatisering Increases
Output Yield, Reduces Energy
Consumption
Copy.... batch time-to-release and
Reduce
rework
Solution:
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Solution:
aspenONE
Benefits: MES for data, workflow,
and performance management
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operated their production processes using a distributed control system
Best
Practice:
• Copy..
Utilize ISA-95 MES design criteria
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resulting in better data flows, higher
•visibility
Copy.. into the production
process, and simplified reporting
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Benefits:
that had several weaknesses, including no capability to manage product
• Increase process yield and output
recipes or provide batch context to production data. These weaknesses
• Reduce in-process wait times
are critical in that the product line is broad with items such as creams
• Decrease energy consumption
aspenONE® Manufacturing Execution System (MES)
manages workflow, data, and batch context while matching
and compiling quality records for release.
A leader in the global manufacture of high-purity hydrocarbons
and oils that require compliance with specifications and recipes and also
their customers are globally-recognized consumer and industrial
• Enhance right-first-time batch
release
product manufacturers.
• Improve inventory turnover
The company’s success depends on their ability to meet and document
adherence to strict quality standards. Products that don’t meet quality
levels are reworked or disposed. Batch test records—part of release
documentation—requires significant coordination between
manufacturing and the quality assurance departments.
AspenTech Partner, ICT Automatisering, was selected to specify, design,
and implement a new manufacturing execution system (MES) that
offers recipe and workflow management, batch content to collect and
manage process data, and integration with barcode labels for printers
and scanners to match quality tests.
With the new system in place, the customer has registered higher
yields, full inventory tracking, faster time-to-release, reduced rework,
and greater process throughput.
Multiple Processes/Recipes Present Data Management
Challenges
Manufacturing operations produces a large number of SKUs, each with a
different recipe. Production is controlled by a distributed control system; it
cannot manage recipes or provide batch context for production data. Each
batch must also have a matched quality assurance test record, documenting
compliance with product specifications. This manual system could not assure
that operations were carried out in the correct order or that batch records
were matched with the required QA testing. The results: product release
delays and high rework potential.
Well-Designed MES Solution is the Answer
The customer’s concrete goals for the system: assure proper order of
About AspenTech
AspenTech is a leading supplier of
software that optimizes process
manufacturing. With AspenTech’s
integrated solutions, process
manufacturers can implement best
practices for optimizing their
engineering, manufacturing, and
supply chain operations. As a result,
AspenTech customers are better
able to increase capacity, improve
margins, reduce costs, and become
more energy efficient. To see how
the world’s leading process
manufacturers rely on AspenTech to
achieve their operational excellence
goals, visit www.aspentech.com.
operations, provide visibility into production status, and create a centralized
infrastructure for management information. ICT Automatisering (ICT)
formulated a design that utilized Aspen Technology’s:
• InfoPlus.21: data collection/access
• Aspen Production Record Manager: automated batch context/genealogy
• Aspen Production Execution Manager: workflow/recipe management
• Aspen Process Explorer: reporting/data visualization
A barcode system was employed, linking batch records with test records by
integrating barcode label printers and scanners via TCP/IP protocol. MES was
integrated with the plant DCS/ERP systems.
Management now has production reporting capability, including individual
batch status—instantly available. With automated data entry, daily production
records are error-free. With systematic recipe management, production
systems comply with best practices under the ISA-95 model. With process
parameters in place when a batch is launched, production is more stable.
Other Benefits
Customer benefits include significant wait-time reductions for production
Worldwide Headquarters
Aspen Technology, Inc.
200 Wheeler Road
Burlington, MA 01803
United States
phone: +1–781–221–6400
fax: +1–781–221–6410
[email protected]
operators and QA lab technicians, along with a measurable decrease in plant
energy consumption. Time-to-release production for shipment has also been
Regional Headquarters
significantly reduced, now that quality assurance data is automatically
matched and available. Reductions in both errors and cycle times have
combined to produce an increase in overall plant output.
About ICT
For more information about ICT Automatisering, please contact:
Martin Bijl
Houston, TX | USA
phone: +1–281–584–1000
São Paulo | Brazil
phone: +55–11–3443–6261
Reading | United Kingdom
phone: +44–(0)–1189–226400
Singapore | Republic of Singapore
phone: +65–6395–3900
Tel. +31 (0)6 51 53 43 29, E-mail: [email protected].
Manama | Bahrain
phone: +973–17–50–3000
© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen
Technology, Inc. All rights reserved.
11-3375B-0813
For a complete list of offices, please visit
www.aspentech.com/locations