Introduction#

In modern manufacturing and production environments, efficiency and resource optimization are critical to maintaining competitiveness. Batch processing is a widely adopted method that enhances throughput, reduces operational costs, and ensures high resource utilization. In Industry 4.0, where automation, real-time data tracking, and smart manufacturing systems drive production, effective Batch management plays a key role in ensuring smooth and scalable operations.

Batch management groups Materials together, allowing them to be loaded, processed, and unloaded simultaneously. This approach not only minimizes cycle time but also ensures that production resources operate at their optimal capacity. Additionally, Batch processing reduces waste, simplifies quality control, and supports just-in-time manufacturing principles.

In Critical Manufacturing MES, the Batch entity is closely integrated with the Resource Job entity, ensuring that Batches are properly managed throughout their lifecycle. It also supports users in identifying compatible Materials for a Batch, based on Step, Product, or Service restrictions. This tutorial will guide users on how to create and manage batches using the Critical Manufacturing MES software, ensuring effective Batch execution and operational efficiency.

Batch Lifecycle#

A Batch typically progresses through several key stages in its lifecycle, from initial creation to its closure when all Materials have been processed and unloaded. These stages ensure that Materials are efficiently managed, tracked, and processed in a controlled manner. The Batch lifecycle is governed by two parallel state models: the System State, which tracks the main Batch progression, and the Batch Material Lifecycle, which follows the state of individual Materials within the Batch.

System State Lifecycle#

The system state lifecycle defines the primary stages a batch undergoes, ensuring structured and efficient processing. Each state transition represents a critical step in batch progression, from creation to finalization.

If no loading model is configured for the Batch, the Materials are automatically loaded when the Release Batch operation is performed. In this case, the Batch transitions directly from Created to Queued, as shown in the diagram below.

graph TD
    A1[Created] --> |Release<br>Batch| A2[Released]
    A1 --> |Cancel<br>Batch| C1[Canceled]
    A2 --> |Unrelease<br>Batch| A1
    A2 --> |All Materials <br>Loaded| A3[Queued]
    A3 --> |One Material <br>Unloaded| A2
    A3 --> |Track-In<br>Batch| A4[In Process]
    A4 --> |Abort<br>Batch| A3
    A4 --> |Track-Out<br>Batch| A5[Processed]
    A5 --> |All Materials <br>Unloaded| A6[Closed]
    A2 --> |Cancel<br>Batch| C1
    A3 --> |Cancel<br>Batch| C1

classDef mermaid_title fill:#fafafa, stroke:#fafafa, stroke-width:0x, font-size:100%, font-weight:200;
classDef mermaid_start fill:#fafafa, stroke:#fafafa, color:#fafafa, stroke-width:0x, font-size:100%, visibility: hidden;
classDef mermaid_initial_state fill:#274b76, stroke-width:0px, color:#fafafa, font-size:100%;
classDef mermaid_final_state fill:#3ba192, stroke-width:0px, color:#fafafa, font-size:100%;
classDef mermaid_canceled_state fill:#b64234, stroke-width:0px, color:#fafafa, font-size:100%;

class Title mermaid_title
class Start mermaid_start
class A1,A2,A4,A3,A5 mermaid_initial_state
class A6 mermaid_final_state
class C1 mermaid_canceled_state

graph TD
    A1[Created] --> |Release<br>Batch| A2[Queued]
    A1 --> |Cancel<br>Batch| C1[Canceled]
    A2 --> |Unrelease<br>Batch| A1
    A2 --> |Track-In<br>Batch| A4[In Process]
    A4 --> |Abort<br>Batch| A2
    A4 --> |Track-Out<br>Batch| A5[Processed]
    A5 --> A6[Closed]
    A2 --> |Cancel<br>Batch| C1

classDef mermaid_title fill:#fafafa, stroke:#fafafa, stroke-width:0x, font-size:100%, font-weight:200;
classDef mermaid_start fill:#fafafa, stroke:#fafafa, color:#fafafa, stroke-width:0x, font-size:100%, visibility: hidden;
classDef mermaid_initial_state fill:#274b76, stroke-width:0px, color:#fafafa, font-size:100%;
classDef mermaid_final_state fill:#3ba192, stroke-width:0px, color:#fafafa, font-size:100%;
classDef mermaid_canceled_state fill:#b64234, stroke-width:0px, color:#fafafa, font-size:100%;

class Title mermaid_title
class Start mermaid_start
class A2,A1,A5,A4 mermaid_initial_state
class C1 mermaid_canceled_state
class A6 mermaid_final_state

The table below summarizes the key states in the Batch lifecycle, describing their roles and how they influence Material handling.

Table: A summary of the Batch Lifecycle, describing the interconnections between the Loading State and the System State diagrams.

Batch Material Lifecycle#

One of the key advantages of Batch management is the complete automation of the Material lifecycle by the system. This ensures effective tracking, processing, and unloading while minimizing errors, enhancing traceability, and improving efficiency. The diagram below illustrates the stages in a Batch Material:

  graph TD
      Start--> |Assign to Batch| A1[Not Loaded]
      A1 ---> |Load Material & <br>Release Batch| A2[Loaded]
      A2 ---> |Unload Material &<br> Unrelease Batch| A1
      A2 --> |Track In| A3[In Process]
      A3 --> |Track Out| A4[Processed]
      A4 --> |Unload Material| A5[Unloaded]

      classDef mermaid_title color:#000, fill:#fafafa, stroke:#fafafa, stroke-width:0x, font-size:100%, font-weight:200;
      classDef mermaid_start color:#000, fill:#fafafa, stroke:#fafafa, color:#fafafa, stroke-width:0x, font-size:100%, visibility: hidden;
      classDef mermaid_initial_state color:#000, fill:#274b76, stroke-width:0px, color:#fafafa, font-size:100%;
      classDef mermaid_final_state color:#000, fill:#3ba192, stroke-width:0px, color:#fafafa, font-size:100%;

      class Title mermaid_title
      class Start mermaid_start
      class A1,A2,A4,A3 mermaid_initial_state
      class A5 mermaid_final_state