Report Manager™ uses Microsoft’s SQL Reporting Services to provide a robust, reliable, and extendable reporting platform for control processes. Report Manager™ can be accessed from anywhere in the plant from a computer or terminal that has network access and a web browser.
Batch, unit, and phase data (includes ingredient usage) are cached in report data queues in the PLC. Each event triggers a transaction that calls a stored procedure in the Report database. Phase-level stored procedures update inventory of ingredients and assign lot-codes to each usage as well as report the start and end time of the phase operation. Batch and Unit level stored procedures report the start and end time of the batch and unit procedures. This information can be used to generate production reports including batch reports and usage reports.
Several of the report types offered include:
Batch Summary Reports
Batch Ticket – The batch summary report is divided into 4 sections; 1) Inventory Usage for the batch 2) Unit Procedure and Phase start/stop times. Includes a link to a Gantt Chart which gives a visual representation of batch timing. Any phase permissive or interlock which delayed batch execution is indicated in the report. 3) Alarms which occurred during the batch 4) Analog trends during the batch. This includes hopper weights, liquid flow rates, temperature, etc.
Campaign Production List – Returns a list of recipe names and # of batches which were completed on the selected equipment. Gives the campaign start and stop times, and includes a link to the Batch Ticket report for each batch.
Alarm History Equipment – Returns alarms from a selectable time period. Alarms can be filtered based on equipment unit.
Alarm History Specific Alarm – Returns all instances of a specific alarm during a selectable time period.
Alarm History Top Ten – Returns alarms in order of highest frequency during a selectable time period, along with the number of occurrences.
Device Status Chart – Displays device status during a selectable time period. This includes whether device is on/open or off/closed, energized or de-energized, in auto mode or in manual mode, or interlocked.
Ingredient Delivery Reports
Ingredient Deliveries – Returns ingredient delivery information during a selectable time period, organized by unit and then by ingredient. The report gives the setpoint, actual amount delivered, % error, and delivery rate.
Ingredient Deliveries Out of Tolerance – Only returns information for deliveries in which the actual amount delivered was out of tolerance.
Inventory Adjustment History – Displays all inventory adjustments for a selected time range. Organized by ingredient and then by location and then chronological list of adjustments. Adjustment information includes lot #, date, amount, and user who entered the adjustment information.
Inventory By Ingredient – Displays current inventory information. Organized by ingredient and then by location and then lists individual lots.
Inventory By Location – Displays current inventory information. Organized by location and then by ingredient and then lists individual lots.
Inventory Lot Trace – For each lot of ingredient, shows which batches used that particular lot of ingredient, and the quantity used.
Inventory Move History – Displays all inventory transactions where an ingredient was moved from one location to another manually. Report is organized by ingredient/location/lot.
Inventory Move History – Displays all inventory transactions where an ingredient was received into a location. Report is organized by ingredient/location/lot.
Recipe Audit List – Lists all versions of a given recipe. The report gives the date/time the version was created, and the user that was logged onto Recipe Manager when the version was created. Contains links to Recipe Audit Version reports.
Recipe Audit Version – For a specific version of a recipe, lists all recipe steps, order of execution, and parameter setpoints.
Usage by Formula Ingredient – Shows ingredient usage during a selectable time period. Report is organized by Recipe (Formula), then by ingredient, then by each phase instance.
Usage by Ingredient Summary – Displays an ingredient usage summary during a selectable time period. Report sums the amount transferred for phase instance, and displays the total.
Usage by Ingredient Formula – Shows ingredient usage during a selectable time period. Report is organized by ingredient, then by Recipe (Formula), then by each phase instance.