System and method for simulation and modeling of batch process manufacturing facilities using process time lines

• US 20040098159A1
• Filed: 11/04/2003
• Published: 05/20/2004
• Est. Priority Date: 02/07/1997
• Status: Active Grant

• Current Assignee: Peter G. Brown
• Original Assignee: Peter G. Brown
• Inventors: Brown, Peter G.
• Granted Patent: US 7,313,505 B2
• Time in Patent Office: Days
• US Class Current: 700/117
• CPC Class Codes: G05B 17/02 electric
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/41885 characterised by modeling, simulation of the manufacturing system
• CPC Class Codes: G05B 2219/31407 Machining, work, process finish time estimation, calculation
• CPC Class Codes: G05B 2219/32248 Create schedule from elementary operations from database
• CPC Class Codes: G05B 2219/32287 Medical, chemical, biological laboratory
• CPC Class Codes: G05B 2219/32301 Simulate production, process stages, determine optimum scheduling rules
• CPC Class Codes: G05B 2219/32354 Divide, analyse process into subprocesses, until elementary unit operations
• CPC Class Codes: G05B 2219/32361 Master production scheduling
• CPC Class Codes: G05B 2219/32364 Simulate batch processing
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A system and method for the simulation and modeling of biopharmaceutical batch process manufacturing facilities using process time lines is described herein. The system employs a four-field delimited string code which specifies the unit identifier code and the iteration value for each of the three levels of scheduling cycle “Unit Operation Cycles,” “Unit Operation Cluster Cycles,” and “Batch Cycles”—of the biopharmaceutical drug production process being modeled. The method includes the step of selecting a sequence of unit operations wherein each of the sequence of unit operations has an identifier code. Next, a set of scheduling cycles is selected for each of the sequence of unit operations. A master table is then referenced, using the identifier code, to obtain operational parameters for each of the sequence of unit operations. A block flow diagram is then generated using the sequence of unit operations and the operational parameters. The method further includes generating a process time line using the operational parameters, the block flow diagram, and the set of scheduling cycles for each of the sequence of unit operations. The process time line—a time line for the beginning and ending times of each unit operation and its associated tasks for the entire biopharmaceutical drug production process—is used as a tool for batch processing and facility design.

Claims

1. A method for simulating and modeling a batch processing manufacturing facility, comprising the steps of:

(1) selecting a sequence of unit operations wherein each of said sequence of unit operations has an identifier code;

(2) selecting a set of scheduling cycles for each of said sequence of unit operations;

(3) referencing a master table using said identifier code to obtain operational parameters for each of said sequence of unit operations;

(4) generating a block flow diagram using said sequence of unit operations and said operational parameters; and

(5) generating a process time line using said operational parameters, said block flow diagram, said set of scheduling cycles for each of said sequence of unit operations, wherein said process time line is used as a tool for batch processing and facility design.

2. The method of claim 1, wherein the batch process manufacturing facility is a biopharmaceutical batch processing facility.