Syncade Overview Brochure Folleto Administrador De Operaciones Inteligentes

User Manual: Folleto Administrador-de-Operaciones-Inteligentes-Syncade

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Syncade

TM

Smart Operation Management
Smart Data. Smart Decisions.

Syncade

TM

Smart Data. Smart Decisions
Syncade suite is an innovative
operations management solution
that provides electronic manufacturing control to optimize across
plant-wide work processes to
increase productivity and maximize
asset utilization.

Optimize resources
across plant functions to
improve performance
Process manufacturers continue to
face many business challenges in a
quickly changing world: global
markets, increased competition,
shorter product life-cycles,
changing product demand and
increased regulatory complexity.
Companies need innovative ways
to improve their production
processes with fewer employees
and tighter resources. But
significant plant performance
improvements cannot be realized
with silos of departmentalized
functions. Integrating information
and activity across plant functions
to optimize resources and
workflow is critical.

Effectively integrate
manufacturing
information to improve
product release times
How many times have you had to
rework or quarantine off-spec
product just because a critical
piece of lab information or unit
performance criteria was missing
when a decision had to be made?
Integrating data and documentation can provide a step
change in productivity by getting
the right information to the right
person in an easy-to-understand
format.

Collaborate work
activity to minimize
variability
Today, most manufacturers have
shift- to-shift variability based on
how well or how poorly
departments work together and
the differences in how individuals
perform their tasks. Optimized and
integrated workflow can reduce
these variables with enforced
operator guidance to ensure
proper processing. Additionally,
real-time verification of operator
training ensures proper personnel
qualifications. The result? Reduced
waste, rework, and errors.

Effective use of production information
increases productivity.
2

Make better business
decisions with
PlantWeb

Optimize operations
management across
your facility

PlantWeb is the
proven digital
plant architecture
that uses the
power of predictive intelligence to
detect operations, process and
equipment problems even before
they occur, so you can move from
reactive to proactive and profitable
management. Syncade smart
operations management suite
extends PlantWeb to integrate
smart real-time, plant-floor data
with your business processes;
thereby giving you the power to
make better decisions and operate
more effectively.

Data and workflow management
are increasingly becoming high
value-add components in a
manufacturing operation.

®

Today, by using the latest
technology and adhering to
industry standards, Syncade suite
integrates across plant functions to
enable optimized operations.
Implemented in a modular,
scalable manner, Syncade suite
allows you to capitalize on four
concepts critical to operations
management:
 resource management
 operations optimization
 integrated information
 quality and compliance.

Syncade suite delivers
value to your
manufacturing
operations:
Reduce
 Cost of goods manufactured
 Non-value activities
 Cost of quality
 Variability in operations

Optimize
 Assets and resources
 Inventory
 Synchronization with demand
 Equipment utilization
 Cycle time

Improve
 Right first time yield
 Data access and integration
 Product release time
 Regulatory compliance.

3

Syncade–Advanced Technologies for Easy
Implementation
Syncade suite is built
with today’s technologies to deliver and
manage information
where and when it’s
required.
Syncade suite takes advantage of
the latest technology:
 Microsoft .NET framework
provides a comprehensive
Service-Oriented Architecture
 Web services communication
and presentation supports
information “push” and access
across firewalls.

 OPC provides a standard for high
speed communications among
real-time systems (Data Access,
Historical Data Access, Alarms &
Events, etc)
 XML, eXtensible Markup
Language standard, allows for
easy data integration structure
 Secure Socket Layer provides
data encryption for security
 802.11a, b, & g wireless enables
mobile communications.
Syncade suite enables you to use
these leading technology advancements to your advantage by
seamlessly integrating data and
applications to improve your
plant’s performance.

Syncade suite lets you implement
functionality as needed–providing
the flexibility to start with one
application module and add
capability based on available
resources and/or business
conditions. Additionally, Syncade
suite allows easy expansion of the
number of users, so you can roll
out the solution to multiple plant
areas, process trains, or sites
as desired.

Integrated
Engineering
for unified
recipe / workflow
development

Syncade
Smart Operations
for real-time,
personalized
interaction

ISA S95 LEVELS

Modularity and
scalability allow
realistic
implementation

Syncade Suite
for order,
resource &
document
management

Historical Data
to collect and
review all
relavent data

DeltaV Batch

DeltaV Process
Operations
for real-time,
personalized
interactions

Advanced Control

to optimize
batch
execution
Smart Safety
to avoid spurious
shutdowns

for reduced
process
variability

Mobile Access

Asset and
Machinery
Management
for improved
reliability

for real-time,
wireless
interactions

PlantWeb Connectivity
for easy, native, integration of plant floor devices

Comprehensive integration across the plant floor.
4

Standards enable
practical integration
Two industry standards, ISA95
Enterprise-Control System
Integration and ISA88 Batch
Control, play a critical role in
enabling the practical integration
of plant operations. ISA has defined
a functional hierarchy model
within a manufacturing operation
that helps companies optimize
functions, processes, and data.
ISA95 Standard, EnterpriseControl System Integration, is
the industry standard for
information exchange between
enterprise and manufacturing
control activities and their
supporting IT systems. It defines
data models, work activity, and
operations management
information exchange. These
functions coordinate the people,
equipment, materials, and energy
within a manufacturing facility.
The activities defined in Levels 3, 2,
or 1 are critical to plant safety,
reliability, efficiency, product
quality, and maintaining
regulatory compliance. ISA95 Level
3 functions coordinate the
resources (people, equipment, and
materials) needed through all
process steps to produce the
end product.
ISA88 Standard, Batch Control,
provides guidelines for the design
and specifications of batch control
systems, including terminology,
batch control language data
structure, and batch control
architecture that defines both
physical and functional models.

ISA95: Enterprise-Control System Integration 1: Models and Terminology;
ANSI/ISA95.00.01— 2000

The physical model is the
hierarchical structure that relates
control equipment and data
communications needed for the
physical areas; including
enterprise, site, area, unit,
equipment module and control
module. The functional model
shows the relationships between
the five types of control: recipe
management, scheduling,
sequential control, regulatory
control, and safety interlock
systems. The procedural model of
ISA88 defines the control that
enables the equipment to perform
a process function: procedure, unit
operation, operation, unit phase,
equipment phase. The ISA88
standard provides a framework for
addressing the modularity and
flexibility that enables a
manufacturer to quickly produce a
new product.
Syncade suite adheres to the ISA95
and ISA88 standards and provides
benefits which directly

reduce time and cost during the
documentation, implementation,
testing, and verification phases of
a project–delivering added value.
 Object-oriented, class based,
scalable designs allows the
software to be reused
 Modular design allows for easier
re-configuration and
redeployment of functionality
 Standard terminology facilitates
clear communications between
automation, IT, quality control,
manufacturing and
management
 Consistent structure and
terminology enables optimized
plant-wide workflow with easy
adoption
 Data models and information
exchange standards enable easy
coordination of resources across
plant functions and easy
integration with other software
applications
 Information exchange provides a
plant-wide data repository with
easy access.

5

Real-Time Resource Management
Reduces Variability
Effectively managing
resources lets you to do
more with less
By optimizing material conversion
and eliminating the use of
unsuitable material you can reduce
waste and rework. Improving
operator material management by
guiding manual weighing and
movement as well as enabling
access to related support
documents can increase
performance. Tracking and
verifying proper equipment use
and status can avoid off-spec
production and re-work. Making
sure your personnel have the skills,
training and qualifications they
need to effectively perform their
jobs can improve the morale of
your greatest asset while
improving their productivity.
Optimize material usage by
managing the full lifecycle of
material workflow. Accurate
material management within a
production facility has a significant
impact on profitability and quality.
Syncade suite helps you effectively
manage materials in real-time to
reduce costs and increase quality
by assuring the correct materials
are used during the correct
process step.

Ensure personnel qualifications by
verifying personnel training and
authority in real-time during
process operation. Syncade suite
enables easy notification of
training requirements, as well as
scheduling and verification of
training sessions.

Reduce operator errors by guiding
the operator through defined
weighing and material
management sequences for
material management operations.
Syncade suite does this by
enabling easy access to all
reference documents such as
Standard Operating Procedures
(SOPs), scale requirements, and
Material Safety Data Sheets
(MSDS).

Material Management
supports the full lifecycle of material

Eliminate paper equipment logbooks
by providing an electronic version
integrated in real-time to smart
devices and is easily accessed via
any Windows device, including
handhelds and PDAs. Enforcing
equipment management status
and integrating reference
documents, such as SOP’s,
Syncade suite helps improve
operator efficiency and ensures
complete and accurate equipment
data is automatic.

workflow and provides a powerful
solution to help you manage the
purchasing, receiving, warehousing,
and shipping of materials. Materials
Management may also be used to
compliment an ERP inventory system
by providing work-in-progress
material management, tracking raw
and intermediate materials
throughout production and supplying
inventory for final products.

Verify resource status and management
so you can do more with less.
6

Equipment Tracking is a

Weighing module provides the

Training & Development

configurable equipment management

ability to manage weighing activities

provides a powerful and flexible

system suitable to be used with any

during manufacturing operations. It

solution for managing all aspects of

type of equipment. It assures that

guides operators as large material

employee training. It has a unique task-

equipment is in a required state

containers are pulled from inventory

based design and intuitive interface

before use and eliminates the need for

and used to weigh out smaller

that make organizing, scheduling,

paper logbooks. It not only tracks

amounts required for specific

delivering, and tracking training easy.

equipment properties and states, but

production needs. Features include

From training requirements definition

also manages definable equipment

full weigh-scale integration, bar code

to course and class scheduling,

events, such as usage, cleaning, and

scanning and printing, material health

Training & Development has

maintenance. Equipment Tracking

and safety display, integration with

capabilities to manage a broad

also provides paperless calibration

enterprise ERP systems, embedded

spectrum of training activities.

record management and electronic

SOP document viewing and a

equipment logbooks with real-time

dispensing dashboard for ongoing

updating using wireless hand-held

weighing operations display at

devices.

a glance.

7

Integrated Operations Improves Efficiency
Managing workflow
across plant functions
to assure right first time
production.
Even highly automated facilities
depend on manual work activities
performed by plant personnel to
complete production. Electronic
Workflow Management assures all
specified manufacturing steps are
performed according to correct
procedure and documentation
is complete.
Syncade workflow capability
enforces sequencing with the use
of electronic work instructions that
guide the operator and provide
access to reference documents
(such as SOPs and MSDS). The
Syncade suite also provides the
capability to coordinate and
control operations workflow,
including both manual and
automated procedures, to assure
the final product has been made in
accordance with the specified
processing requirements and all
documentation is complete and
accurate.
Ensure consistent workflow by
implementing a single order or
workflow that spans both step-bystep manual activities as well as
automated processes. Syncade
suite provide comprehensive
approach to workflow to help you
optimize resources across plant
functions for reduced operator
errors and process variability.

The single order / workflow feature
in Syncade suite enables
comprehensive documentation
records to be generated in realtime–flagging omissions or
inaccurate data during processing,
as well as enabling review by
exception.
Synchronize disparate functions to
improve operations performance by
integrating real-time operations
management systems with
enterprise business systems. For
example, if order management and
production scheduling are closely
linked to resource allocation and
operations, capacity utilization can
be maximized and inventory can be
minimized. Another example is to
integrate QC lab activities with
plant floor operations to verify
quality, support operational
decision-making, and to enable
release by exception.

Reduce the engineering effort
required to integrate systems by
using standards-based modular
software. Syncade suite, based on
ISA88 standards, provides the
framework to address order and
workflow modularity and flexibility
for easy design.This comprehensive
scope and bi-directional capability
directly reduce the time and cost
of implementing, documenting
and testing solutions.

Recipe Authoring gives you
Avoid missing or inaccurate data
during manufacturing operations to
reduce rework or scrapped product
and improve product release time.
By recording and verifying data
from your production activities as
events occur, Syncade suite helps
you detect and correct missing or
inaccurate data to ensure a
comprehensive production record.
By integrating information from
various sources, such as lab results,
Syncade suite can provide critical
information in real-time for
improved decisions and actions.

a quick and easy way to create
integrated orders and recipes
consisting of automation and manual
workflow functions. These recipes and
orders are created using standardized
libraries, modular building block
construction and drag and drop
design tools. Recipe Authoring makes
it easy for non-technical people to
design and implement manufacturing
activity.

Connect work activity across functional
silos seamlessly.
8

Electronic Workflow

Order Management

Scheduler is a powerful tool to

provides completely paperless

provides scalability and oversight for

transform the high level production

manufacturing operations. Electronic

all production orders, based on real-

plan into specific order and

work instructions eliminate typical

time needs. This solution integrates

equipment schedules. Scheduler then

manual and paper-based execution

enterprise resource planning (ERP)

tracks or allows adjustments to

and the associated management

production orders with plant floor

specific equipment and materials as

errors. When Electronic Workflow is

systems and provides order

changing plant floor conditions

integrated with other Syncade

management for facilities that do not

require them.

modules, it also performs real-time

have an ERP system in place.

permissive checks, such as verifying
material and equipment or confirming
operator training which reduces
common non-compliance deviations
and improves release management.

9

Comprehensive, Verified Information
Supports Better Decisions
Standards-based
systems validate
information and enable
easy and maintainable
solutions.
Plant-wide information integration
optimizes resources and enables
interdependent activities to be
effectively synchronized. By
validating this data and putting it
in relative context for consumption
by users and other applications,
Syncade suite creates the
information for collaboration and
improved decision making. Using
solutions that adhere to industry
standards helps ensure
maintainable functional
integration. Syncade suite is easy
to use, integrate and maintain
because it’s built on industry
standard OPC and .NET based web
services.

such as incorrect material charging
or equipment malfunction, is
flagged in real-time and brought
to the attention of appropriate
personnel. Wireless access for
expanding the capability of these
solutions to mobile workers
ensures all plant floor people have
the best information at their
fingertips.

Achieve higher performance by
accessing all the available data in
your operations. With Syncade
suite’s Process Analyzer, analysis
tools and access to comprehensive
operational data helps you gain a
clear perspective of how to do
more with your existing facility
without large capital expenditures.

Provide the right information in the
right format to the right person by
customizing information to their
needs. With so much data
available, it can be difficult to
analyze the data and determine
what is important. But with
Syncade’s Operations Dashboard,
user-customized web parts
supported by web service access
provide critical information,

Integrate smart, real-time information
to your business systems.
10

Operations Dashboard

Message Broker provides

Process Analyzer lets you

provides a window into your manufacturing operations. With snap-in
functionality and easily understood
metrics, it gives operators and
managers the tools they need to
effectively compete in today’s
changing world. Operations
Dashboard provides a completely
configurable workspace that allows
managers and other personnel to
subscribe to key modules and data
sources they need to perform their
jobs. Customized, user-specific
displays focus activity and minimize
distractions. These enable the right
information to be viewed by the right
person without extraneous and
potentially confusing data to be seen.

standard, configurable interfaces to

mine data from multiple work

specific complementary solutions

activities and summarize it into

such as an ERP or laboratory

consolidated information views for

information management system

business performance analysis. Easily

(LIMS). Standardized transactions and

maintain work context while exposing

queries make real-time information

opportunities for improvement.

exchange easy, so the right data gets
from one application to the next
without errors or delays. Using
industry standard Service-Oriented
Architecture streamlines parameter
connections between the
applications.

11

Managing Paper to Reduce Errors
Managing documents
saves time and money
Documentation is a necessity of
effective operations and includes
many types of documents. These
documents support a wide array of
audiences, such as operations,
maintenance, and quality. They
also support various information
types, such as production records,
SOPs, order forms, and lab reports.
The development and change
management of documentation
has been inefficient and time
consuming.
Ensure the current practices are
being used across operations and
across sites for optimal
performance. Syncade suite’s
Document Control and Archiving
makes documents that are
approved and effective
immediately available to
operations personnel to ensure
best practices are being used.
Using electronic document
management, Syncade suite
enforces the consistent use of the
most recent approved version.
Make document collaboration,
routing, and approval intuitive by
addressing the complete
development lifecycle. This effort
includes online document storage,
single- and multi-document
change control, review and
approval automatic routing,
document check-in and check-out,
version management, archived

records management, and
printing–all supported by Syncade
suite. Additionally, Syncade suite
provides the flexible change
management you need, with
highly configurable change
request workflows. This includes a
conditional review option, serial
and parallel review and approval,
role and user-specific assignment
feature, and delegation
management of review and
approval assignments.
Mimic paper-based records for easy
adoption within existing facilities.
By electronically replicating paperbased records, your personnel can
easily adapt to the use of electronic
technology. It provides the first
step to your paperless
manufacturing vision. And, it
maintains a consistent look and
feel when regulatory personnel
review both paper-based and
electronic documents.
Ensure proper access and
authorization for all operations
processes by creating user
privileges and defining user groups
once for use throughout your plant
operations. Enforce proper
document workflow based on user
privileges and configured
protection and access.

Document Control and
Archiving is an electronic
document management system
designed specifically to meet
regulatory requirements, including
the U.S. Food & Drug Administration
(FDA) and environmental agency
regulations. Users can maintain full
control of their documents, including
version management and electronic
routing, review, and approval.

Improve compliance with confidence.
12

Federated Document
Search allows for document

Batch Record Printing

Security and Audit is a

provides a controlled solution for

powerful solution designed to

searches across multiple repositories

producing consistent documentation

manage application security, maintain

and servers. This capability enables

for paper-driven processes. Issuing

a comprehensive audit trail of events

comprehensive collaboration by

consistent records that meet

for all of the Syncade applications and

personnel, regardless of location.

regulatory requirements is much

provide FDA 21CFR Part 11 control for

Additionally, approved and effective

easier with the pre-stamped lot

electronic records and signatures.

documents can be easily shared

number feature. This application also

across locations to ensure best

maintains an electronic audit trail of

practices are being followed.

document information, including a
listing of all documents printed, lot
numbers, requester, and date and
time printed.

13

Rely on Emerson Expertise to Deliver
Today’s most successful Process expertise
Emerson is a leader in automation
projects call for
and has developed centers of
partnering with proven
excellence and expertise within
key, process manufacturing
experts who can
industries. Our experience in
consistently deliver the
successfully automating FDA
best available technology regulated facilities is unmatched.
Expertise in the chemical, food &
to ensure efficient
beverage, life sciences, oil & gas,
petro-chemical, refining industries
operations.
From concept through planning,
implementation, production and
ongoing operations, highly
experienced Emerson professionals
work closely with you to ensure
compliance and ease of operation
by providing:
 business justification
 execution
 multi-vendor management
 procurement & delivery
 ongoing support.
Emerson capabilities and
experience are especially valuable
when time is at a premium. A
single point of accountability for
the entire instrumentation and
automation solution makes a
crucial difference.

combined with clear leadership in
today’s digital technologies makes
Emerson the logical choice for your
project needs.

Expert project
management
Emerson project managers have
significant experience in
understanding customer needs,
developing feasible project plans,
mobilizing the necessary
resources– from around the globe
if necessary– and delivering the
project to the set objectives.
During the different phases of the
project, the communications with
all project sponsors and
stakeholders are critical to the
success of the project.

Key technical lead
engineers
Emerson technical lead engineers
bring years of industry and
automation experience and the
ability to lead project teams to
efficiently deliver projects. Lead
engineers draw on proven
engineering methodologies from
functional requirements through
startup, documentation, and
training.

Emerson–Consider It Solved.
14

Proven methodologies

Lifecycle services

Innovative Leader

Schedule and cost constraints are
common challenges for most
projects. But they can lead to a
breakdown of processes and
procedures, which in turn can
adversely impact project and
installed system performance.

Emerson is with you long after your
process has started up. In today’s
world, predictive maintenance
ensures continued smooth
operations. Our Asset
Optimization services take
advantage of today’s digital
technologies to help you squeeze
more performance from your
critical assets than previously
possible. And our global
SureService support organization
is ready 24 hours a day, 7 days a
week to support you through the
life of the facility.

With rigorous planning and sound
management, Emerson continues
to invest considerable capital and
resources into research and
development to bring you new
technologies that deliver greater
value and efficiency.

Emerson's project execution
methodology addresses these
issues by optimizing requirements
definition and system design,
eliminating multiple changes and
inconsistent interpretation of
regulatory or other industry
specific requirements. This
simplifies testing requirements,
and optimizes the deployment of
project resources.
From the early design phase
through the engineering,
documentation and installation
phases, this methodology provides
structure, clear focus on business
objectives, and definition of
project team member roles. The
methodology provides a modular
and structured approach to the
design and configuration of the
integrated solution–making the
overall design easier to implement,
test and support, with
minimal risk.
With experience gained through
hundreds of thousands of project
service hours, our project
methodology helps you
aggressively manage your projects.

Emerson–a partner you
can trust
Emerson Process Management
leads the automation industry
worldwide in providing technology
and solutions to improve process
manufacturers’ performance.

Strength and Stability
For over 100 years, Emerson has
been providing innovative process
automation solutions with a
commitment to total quality, plant
safety, and dedication to meeting
customer expectations. Emerson
Process Management is a leading
supplier of process automation
solutions worldwide. We offer the
financial strength and stability
required not only for large,
complex projects, but also for
continued long-term support and
management of these assets.

15

Customers who have requested this brochure have
also requested the following brochures:
 Project Engineering
 Emerson Automation Contracting
 Best in Batch–DeltaV Digital

Automation System
 Operational Excellence (OpX) Guide

©Emerson Process Management 2009. All rights reserved.
For Emerson Process Management trademarks and service marks, go to
http://www.emersonprocess.com/home/news/resources/marks.pdf

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their
accuracy, they are not to be construed as warrantees or guarantees, express or implied, regarding the products or services described
herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the
right to modify or improve the design or specification of such products at any time without notice.

Emerson Process Management
12301 Research Blvd.
Research Park Plaza, Building III
Austin, Texas 78759 USA
T +1 512.835.2190
F +1 512.832.3443
www.EmersonProcess.com/Syncade

Form B-000030 / Printed in USA / 5K AQ / 04-09



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