The Foundation is a required module and is the “database & foundation” for all other modules to connect to. Besides the Database the foundation includes the following tools:

  • Resource Manager
  • Reports
  • Security
  • Database
A common problem in the Flavors, Fragrance & Beauty Care industries is the complexity of scheduling thousands of ingredients, some of which require SOE, into tens of thousands of recipes. Furthermore, this issue worsens due to its necessity to fit into a consistently changing schedule that experiences disruption, which continually forces reconsideration and revision of pre-established schedules. BatchMetrics solves this problem with its Dynamic Scheduler/Optimizer, which assists in decision-making by providing rules-based artificial intelligence and real time visibility, preventing undesired downstream consequences.

Real Time Visibility to all activities lab, plant and enterprise wide. This includes:

  • Receiving
  • QC Quarantine
  • Planning
  • Released Process Orders
  • Production
  • Robots
  • QC
  • Packout
  • Applications Lab
  • Sample Lab
  • Staging
  • Automation
  • Easy Operations Schedule Adjustment
  • Constant Real Time Visual & Graphical Feedback
  • Sync with ERP
  • Detailed view of received Process Orders
  • Calculation of expected Pour Time
  • Calculation of Process Orders in specific Queues
  • Ability to adjust any parameter in a Process Order (with Security Clearance)
  • Ability to move items between sub mixes
  • Ability to release a Process Order into production
  • Adjusting and releasing of a halted order
  • Process Order creation
  • Canceling/deleting of a Process Order
  • Dynamic overview of process dependencies and inventory shortages
  • Client Rules-based Artificial Intelligence
  • Splits into different work queues
  • Sequential releases (such as a raw material that will need to thaw)
  • Planning and analysis tools to calculate demand and show replenishment requirements
  • Ability to view pre-picked material for Process Orders
  • Dashboard overview of all work queues and Process Orders
The BatchMetrics Bridge enables seamless integration between ERP systems (such as SAP), Inventory Systems, LIMS Systems, Robots, Creative System, Project Management Systems, HMIs, PLCs, Kardex, and Schedulers to BatchMetrics.

  • The Bridge can speak multiple languages such as:
    • XML
    • Xi
    • iDOCS
    • Flat Files
    • CSV
    • RFC
  • Protocols already built for:
    • Scales
    • Kardex Storage & Retrieval Systems
    • White Storage & Retrieval Systems
    • Contexa Robots
    • VanWyk Robots
    • Fricke Robots
    • PLCs
    • HMIs
  • Each transaction is error checked in a web based visible portal
  • Error messages are sent out in the form of via formal text or email
Initially designed in 1999 as a tool to electronically capture weights using a scanner and scale, the Workbench now covers almost all of the work requirements of compounders, whether in the lab or on the shop floor.

  • Electronic Weight Capture
  • Barcode verification (confirming that the correct materials are added to the batch)
  • Notification of all inventory shorts
  • Over-pour protection/correction
  • Work queue of specific/all process orders (each drillable with progressive disclosure)
  • Fixed or Mobile
  • “Peak of the Pour” data collection
  • Logs all events easily and accurately for all pours and compounder actions
  • Adjust Batch size based on several factors
  • Solutions/Coeur on the fly
  • Substitute Raws on the fly with QC Rules/Approvals
  • Connections to MSDS info with operator prompts and acknowledgments
  • Very intuitive graphical user interface (just scan and pour)
  • Put orders on hold and restart from that point at any time
  • Automatic prompts to use ‘close to expiration’ Raws
  • Preventative Operator error avoidance (aka no double pouring)
  • Auto-selects the optimized path of inventory pick up
  • Comment field
  • Queue of Review
  • Access to all info (including locations) in Inventory Workbench
  • One click inventory delivery requests
The BatchMetrics Inventory module is designed specifically for the unique needs of the F&F Industry.

  • Ability to view all material in all areas including Robots, Kardex and Pre-Picked material
  • Dynamic ABCD analysis
  • Integrated cycle counting
  • Location & Container Barcoding
  • Refill Expiration & Retest Requirements
  • Lot Generation and Traceability through every step/sub
  • Integrated with:
    • Regulatory
    • ERP systems
    • Material Master
    • MSDS
    • HACCP
    • PDAs
    • Fork Lifts
    • Scale connectivity
    • Automatic Barcode printing to pre-specified printers
    • Staging
    • Process Order dependencies and shortages
    • Container-based inventory
    • FIFO support/enforcement
    • Container zero ability
    • Priority 1 material notification
    • Inventory transfers and putaway
    • Consolidated picking & putaway with locations
    • Optimized Picking from Kardex, Hives, Warehouse
    • Receiving and QC quarantine
    • Global ability to change parameters or QC status enterprise-wide
    • History, Material Master, Lot Details, Locations, Zones, Properties, Notes
No longer will QC/LIMS be considered an island. QC/LIMS is designed to be an integrated module of the BatchMetrics Total Process Solution, providing visibility to the wealth of information in QC/LIMS, as well as velocity to the internal supply chain. Additionally, QC/LIMS is designed to be an enterprise-wide solution, allowing authorized users to deploy global changes.

  • Ability to view all incoming raw materials, inventory, equipment, external micro testing and Process Orders in Dashboard queue
  • Custody transfer of samples in and out of QC/LIMS
  • Ability to dynamically generate any set of test parameters as well as select which site worldwide these parameters will be driven out to. A few examples of tests are:
    • Color
    • Appearance
    • Specific Gravity
    • Density
    • Flash Point
    • pH
    • Percentage Solids
    • Moisture
    • Solubility
    • Particle size
  • Separate queues for incoming Raws and Compounding Products
  • Each queue is drillable with progressive disclosure. Examples of data fields include:
    • Received Date
    • Product Number
    • Description
    • Lot Number
    • Requested Quantity
    • Received Quantity
    • Measure Units
    • Vendor Name
    • Purchase Number
    • Storage Location
  • Test forms are automatically generated
  • Immediate notification of “hot jobs” or Level 1 compounds
  • Different tests of the same product for different customers
  • ‘Retesting required’ notification for soon to expire materials
  • Embedded comments
BatchMetrics electronically links and logs all activity in the lab and shop floor. The data is stored and is accessible through web-based reports. Although our list of reports is extensive, we understand we will not be able to provide you with every report imaginable. Here are the reports we offer:

  • Operator Productivity Report
  • Full Lot Traceability
  • Custody Transfer (i.e. from production to QC)
  • Pour History based on Inventory/Area/Resource/Shift/Operator/etc.
  • Product Tracking and Genealogy for WIP & Finished Product
  • Yield Reports
  • Material Usage Reports
  • Event Tracking Reports
  • Warehouse Requests
  • Equipment Utilization
  • Inventory History
  • Inventory Shortages
  • Expiring Materials
  • QC Reports
  • Cycle Counting Reports
  • “Process Orders” Reports
  • Variance per area and/or compounder
  • Production Event Tracking
The BatchMetrics web-based portal will enable all authorized employees to see the status of all materials, reports, Bridge transactions, Inventory issues, Process Orders status, etc. Part of the purpose of the Portal is to allow employees who are not directly working on manufacturing the Sample/Process Order (i.e. customer service, purchasing, upper management) to view this pertinent information without any time or communication delays.
Unlike Rockwell, GE, Siemens and other automation companies, BatchMetrics Automation can provide a Total Process Solution, linking ERP, MES, HMI, PLC, Sensor, F&F Knowledge, and Resource Manager.

  • A storage location can be changed in the ERP system, which can drive changes into BatchMetrics Inventory/Scheduler/Resource Manager automatically
  • .NET BatchMetrics components can be dropped into all of the major HMI packages
  • All code is built logically, with devices connecting to units connecting to areas
HACCP is a module that can help address the analysis and control of biological, chemical, and physical hazards, from raw material production to procurement and handling. In doing so, BatchMetrics helps to comply with the new FDA Food Safety Modernization Act and SQF.

  • Ability to track the “cleanliness” of all pots, pumps, hoses etc.
  • Lockout of all components that are not clean
  • Electronically checks to assure that components have been cleaned
  • Automatically logs all information
  • Integrated with ERP or Project Management software for packing, label printing, container requirements, documents, Process Order completion, etc.
  • Integrated with scales for full traceability and real time reporting of scrap, yield loss, and actual material packed per container
  • Integrated with QC for release to ship, as well as material hold of any material in the Process Order
  • Lockout of all components that are not clean
  • Enforce FIFO of containers
Resource Manager is an administrator level tool that allows the client to manage all resources connected to the system. The BatchMetrics philosophy is to make the system user configurable. Hence, we expose all areas, as it allows users to modify rules dynamically. These “defined resources” are configurable per site and include, but are not limited to:

  • Plants
  • Areas or Work Queues within the plants
  • Units such as Reactors
  • Equipment such as a valve within the unit or standalone like a barcode printer
  • Stations
  • Containers
  • User Levels
  • Security Levels
  • LIMMS/QC Parameters
  • Inventory location
  • Dynamic views of the “Process Orders” in process in each Queue
  • Dynamic views of the Customer Order and any additional “Process Orders” from that client that will be needed to ship complete
The PDA offers users the full functionality of the Production and Inventory Workbenches, all on a small portable scanning device.

  • Available in handheld form, or mounted on a forklift
  • Pop-up warnings for Priority 1 materials
  • Real time Material requests from compounders or QC/LIMS
  • Scanners are available in Class I Div. I
Many ERP & Creation systems have the process (Heat, Mix, etc.) information that is formatted in free form text. This free form text is available for the compounders to view, but it is not embedded into the recipe as steps to be completed. With BatchMetrics Recipe Manager, the process steps are embedded into the recipe:

  • BOM recipes downloaded from the ERP or Creative system can be automatically linked to a Process Recipe, creating a Master Recipe
  • Metrics can be applied to process-related steps, rather than simply relying on text stating “Mix Well”
  • If PLCs & HMIs are present, the Master Recipe can split into the different areas, and the parameters needed for the automated areas can be automatically downloaded into the PLC & HMI
  • Recipes can be set up into classes and sub classes, such as Soups/Tomato Soups/Kosher Tomato Soup
  • Phases & Steps limited only by PLC memory constraints
  • Steps residing within Phases can be set up in sequential or simultaneous fashion
Advanced diagnostic and reporting tool. Like Excel on Steroids.

  • Easily visualize data using scatter plots, histograms, multiple trend charts, frequency analysis, pivot table stack graphs and stack histograms
  • Various model-based multivariate charts
  • Charts are linked to one another and the user has full data-brushing capability, as well as the ability to link an individual point on the various graphs
  • Problem definition
  • Create non-linear multivariable models of your process
  • Knowledge Extraction – determine I/O relationships, Cause Analysis, Sensitivity Analysis, Process Rules and ‘what if’ scenarios
  • Benefit Estimation – The basis of benefit estimation is constrained optimization around the model generated
With BatchMetrics, you can go beyond the standard costs of adding a multiplier in addition to the raw material costs. A fully deployed BatchMetrics TPS will capture all time and resource requirements, which will provide the true cost to “manufacture”.

  • Time & resource metrics can be applied to all steps including:
    • Receiving
    • QC Quarantine
    • Planning
    • Released Process Orders
    • Production
    • Robots
    • QC
    • Packout
    • Applications Lab
    • Sample Lab
    • Staging
    • Automation
  • Costs can be associated with all resources including:
    • Equipment
    • People
    • QC tests for subs and final product
    • Pack Out material
    • Yield Loss
    • Scrap