Continuing the theme “Using skills development techniques to understand and solve business problems”, Mishal Adkins of Emerson p.shared a great story about how a manufacturer justifies using technology to achieve its business goal. to reduce variance, eliminate excess work and improve production efficiency, especially the product approval process.
The current method of working with documents includes batch logs and portable data transcriptions throughout the entire workflow. As a result, batch time was not optimal due to the time required for quality and production departments to review print journals. In addition, the effort required to release the package included many non-recoverable steps generated. Over 20% of the atypical events detected were caused by manual error recording. Failure in the verification process will result in economic benefits in the form of faster batch release cycles, less labor, and fewer batches being quarantined or discarded.
A Customer Price Assessment System (MES) was installed at various sites in the company, which, however, was focused onen on the registration of simple automated processes. Some examples of integrated data trend records as well as comments and electronic signatures. In fact, the system was minimally connected to the control system via OPC. Another big problem was that MES was personalized for each site, and the vendor’s approach is also a “configure, definitely tune” approach to site validation.
Achieving the desired level of end-to-end security will require tight integration between the MES and the management program. This fail-safe approach required additional accessories for complex automated and manual analyzes with long residence times, which, of course, were built into batch reports.
Michalle described the goal of the project and the team to achieve organizational consensus during the project to develop and identify features. The project team consisted of representatives from key departments with a global sponsor of the site management. Team members represented operations, quality, IT, engineeringd, automation, plant management, business management and therefore validation.
An important part of the nature of the process is to provide a magic size to illustrate how error checking is likely to be done and how requirements will be met. The team monitored business process excellence and recruited members of the company’s automation and information technology (IT) group.
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The magic period was 3 months and included an integrated MES recipe with their DeltaV control system. The team included members of a life sciences consultant team to train system configuration, validate concept improvements and test implementation, support presentations, and develop tasks for the Syncade project.
MES ideas for the prototype included recipe creation, electronic batch logs, device tracking, material management, weighing and dispensing, document control and archiving as modules of the security and auditing application.
The process of developing functional requirementsThe brand was born around the first draft of the brand. The paper records were deconstructed by mapping each bit of data entry arenas and parameters in DCS And mes. Definitions have been developed for S88 block operations, parameters, recipe values, operator text displays, flow logic introductory steps, guidance requirements, and signatures.
Based on this iterative process, a prototype was developed, built and tested. The prototypes were presentations divided into small groups by department to distribute specific questions and comments from the point of view of the department. A rationale based on the Operational Excellence Process was obtained and tangible benefits were identified through the improvements to Value Watch in terms of reduced processing time, verification time, data entry and post-processing of settlement documents.
Other tangible benefits were the reduction in diversity, storage, material waste, and deviations / comments on events. The intangible benefits included more attention to the real quality of design, greater availability of information and some of the powers that have been given to employees at all levels. This approach has better organized content to identify areas for improvement, including actually identifying situations for applying analytical technology methodologies (PAT). The benefits were quantified and return on investment (ROI) calculations were performed for the entire project to justify it.
The prototype became a true proof of concept for both the integrated MES technology and the strategy for implementing and validating the construction project. The project begins on the way to achieving the set business goals. Michalle and his team of speakers launched the Ask the Experts page to discuss their challenges in life sciences.
