Creating Concise Custom Reports in SIMATIC BATCH Using Application Templates

To condense standard 200-page SIMATIC BATCH reports into concise 1-to-2 page executive production summaries in PCS 7 V8.1/V9.0, implement the Siemens configurable sample report template (Application Example SIOS Entry ID 68125590). This template allows engineers to hide verbose recipe hierarchy levels, intermediate phase logs, and routine operator messages using Crystal Reports or Microsoft SQL Server Reporting Services (SSRS) suppression formulas. Configuring the template to display only the batch header, unit allocation summary, and key critical process parameters (such as water volume, mix time, transfer volume, and heating duration) creates concise audit-compliant batch records without manual data extraction.

SIMATIC BATCH Standard Reporting Architecture and Data Bloat

SIMATIC BATCH provides comprehensive ISA-88 recipe execution and automated electronic batch recording. By default, the standard SIMATIC BATCH report generator prints an exhaustive, granular audit trail of every recipe element across all unit operations: recipe headers, RUPs (Recipe Unit Procedures), ROPs (Recipe Operations), technological phases (EPH), step state changes, setpoint alterations, continuous archive trends, and all associated process alarms.

In multi-unit facilities (such as a 10-unit process cell), this standard report frequently exceeds 200 to 500 pages per batch run. For plant managers, warehouse logistics, and quality assurance personnel, this volume is impractical. Production stakeholders require a streamlined, 1-to-2 page summary capturing batch ID, product code, start/end timestamps, unit allocation matrix, and key critical quality attributes (CQAs).

Configurable Sample Report Template Architecture (SIOS 68125590)

To resolve reporting bloat, Siemens published the application example 'Configuring of SIMATIC BATCH Reports using a practical example' (Entry ID: 68125590, companion to 34083565 and 34083950). This solution delivers a customizable report template built on Crystal Reports / SSRS that features dynamic filtering rules:

Object Type Filtering: Hides intermediate step transitions while keeping top-level unit procedures.
Parameter Flagging: Displays only parameters flagged as 'Record-Relevant' in the recipe editor.
Alarm Journal Filtering: Filters out high-frequency warnings, printing only critical abort and trip messages.
Pre-Engineered Summary Layout: Combines header data, unit timelines, and final ingredient totals onto a standardized 1-page cover sheet.

Report Generation Strategies and Tool Comparison Matrix

The following table compares approaches for producing concise batch summaries in SIMATIC PCS 7:

Reporting StrategyToolset UsedEngineering EffortOutput ConcisenessAudit Compliance (21 CFR Part 11)Standard BATCH ReportBuilt-in Report GeneratorZero (Out of the box)Poor (200+ verbose pages)100% Fully CompliantConfigured Template (SIOS 68125590)Crystal Reports / SSRS TemplateLow (Template modification)High (1 to 2 pages)100% Fully CompliantXML Batch Data ExtractionXML Parser + Excel / Python ScriptMedium (Custom scripting)Maximum (Custom dashboards)Requires custom validationProcess Historian / Information ServerSIMATIC Information ServerMedium (Web dashboard design)High (Automated PDF/Excel)High (Enterprise reporting)

Step-by-Step Configuration of Concise Custom Batch Reports

To deploy and configure the concise batch report template:

Download the Application Template:
- Retrieve the sample report package from Siemens Industry Online Support (SIOS Entry ID: 68125590).
- Unpack the customized report template file (.rpt or .rdl).
Open Template in Report Designer:
- Open the template in the Crystal Reports Designer (or Visual Studio SSRS Designer for newer releases).
- Navigate to the Section Expert.
- Locate sub-report sections for Phase Details (EPH_Section), Step Events, and Low-Priority Alarms.
- Enable the Suppress (No Drill-Down) formula condition on verbose details.
Format Critical Process Parameters Table:
- In the Summary Section, create a parameter table linked to Batch_Actual_Values.
- Add explicit fields for key variables: Water_Volume_Actual, Mix_Time_Actual, Discharge_Volume, and Heat_Duration.
- Add unit allocations and batch runtime calculation formulas.
Deploy Template to SIMATIC BATCH Server:
- In the BATCH Control Center (BCC), navigate to System Settings -> Report Templates.
- Import the modified report template and assign it as the default print template for the target master recipes.
Generate and Validate Batch Report:
- In BCC, select a completed batch, right-click, and select Print -> Preview Report.
- Verify that the generated report condenses into exactly 1 or 2 pages containing all essential parameters.

Verification

Verify custom report output:
1. Run a test batch in SIMATIC BATCH or open an archived historical batch.
2. Execute report generation from the BATCH Control Center.
3. Confirm that the total page count is constrained to 1 or 2 pages.
4. Audit the printed values against actual process data in the controller to confirm that water volume, mix time, and transfer weights match physical totals exactly.
5. Ensure batch signatures, unit allocation timestamps, and batch status (Completed) are clearly visible.

Limitations and Operational Precautions

Regulatory Audit Archives: While operators receive the 2-page summary, the complete, uncompressed electronic batch record must remain archived in the SIMATIC BATCH database to satisfy regulatory GMP / FDA inspections.
Template Backup: Store custom .rpt / .rdl files outside default installation folders; PCS 7 service pack updates may overwrite standard template libraries.
Crystal Reports Licensing: Modifying .rpt templates requires a licensed copy of the Crystal Reports Designer matching the version bundled with your SIMATIC BATCH release.

Engineer FAQ

Can I extract batch data directly from archived XML files?

Yes. SIMATIC BATCH exports completed batches as XML archives. External software (Python, Excel VBA, MES) can parse the XML schema to generate custom reports, though template modification is simpler.

Does using a custom report template break electronic batch record compliance?

No. The template merely changes the presentation layer; the underlying historical database remains fully cryptographically secured and compliant with 21 CFR Part 11.

How do I restrict the report to print only specific recipe parameters?

In the BATCH Recipe Editor, mark desired parameters with the 'Record-Relevant' attribute, and configure the report template formula to suppress parameters where IsRecordRelevant = FALSE.

Can SIMATIC Information Server be used instead of Crystal Reports?

Yes. SIMATIC Information Server connects directly to Process Historian and WinCC/BATCH archives to generate scheduled, web-based, concise dashboard reports in PDF and Excel formats.