Amgen, Inc.: The No-Impact Migration – Upgrades in a Validated Environment

939 views
595 views

Published on

Safe production of cutting-edge biopharmaceuticals relies on advanced manufacturing technology. At its Thousand Oaks, California facility, Amgen develops and manufactures innovative human therapeutics, but needed to update legacy control systems to keep up with production demands. Through a series of scheduled phases, Amgen migrated to a new control system with a centralized architecture in a validated environment without effecting ongoing operations. Virtualized servers helped reduce cost and impact of the transition.

Published in: Technology, Business
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
939
On SlideShare
0
From Embeds
0
Number of Embeds
37
Actions
Shares
0
Downloads
19
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Amgen, Inc.: The No-Impact Migration – Upgrades in a Validated Environment

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Amgen, Inc.: The No-Impact Migration - Upgrades in a Validated Environment
  2. 2. Innovative Strategies in Migrating Legacy PLC5 Control Systems Tom Lopez, Amgen Richard Kleinfeld, M+W Automation
  3. 3. Agenda • Company Background • CEMS Implementation • UCS Implementation • Q & A
  4. 4. Amgen  Today World’s largest independent  biotechnology company ~ 20,000 employees > 75 countries Reached millions of patients
  5. 5. For additional information about Amgen products, including important safety information, please visit amgen.com; Kyprolis® (carfilzomib) is developed and marketed (except in Japan) by Onyx  Pharmaceuticals, an Amgen subsidiary; NEXAVAR® (sorafenib) is developed and marketed under collaboration and co‐promotion agreements between Bayer Healthcare and Onyx Pharmaceuticals
  6. 6. M+W Automation (MWA) Competence Network AMERICAS EUROPE ASIA/PACIFIC 270 Employees Headquarters: • Danbury, CT, USA 630 Employees Headquarters: • Ludwigshafen, Germany 60 Employees Headquarters: • Shanghai, China • Austria • Belgium • Czech Republic • Germany • Ireland • Poland • Russia • Switzerland • Slovakia • The Netherlands • Turkey • Canada • Puerto Rico • USA  Chemicals  Pharma & Biotech  Food & Nutrition  Automotive  Semiconductor  Oil & Gas, Mining Industries
  7. 7. Background: • Critical Equipment Monitoring System (CEMS) • Windows 2000 Upgrades initiated discussions for strategic review/replacement of obsolete hardware/software 7 CEMS Implementation
  8. 8. 8 CEMS Implementation Background: • Main Buildings in scope (I/O count): • BA (120) • BB (45) • BC (80) • BD (240) • BE (720) • BF (180) • BG (200) • BH (690) Total Buildings Upgraded: 11 Total I/O: 2615 • Other Buildings/Sites: • BI (300) • SiteJ (45)
  9. 9. 9 CEMS Implementation Business Case Detailed Design Implementation /Testing Commissioning Traditional New Design Benefits Stand-Alone Installations Rockwell Client-Server- architecture Fully integrated design, Centralized software, Ease of maintenance/ change management iFix HMI – Rockwell PLC integration Rockwell HMI – Rockwell PLC Amgen standard, Ease of integration, minimize training/ customization between vendors iFix Data Collection/ Trending PI Interfaces for each building Amgen standard, more robust & reduce complexity/SPOF
  10. 10. 10 CEMS Implementation Business Case Detailed Design Implementation /Testing Commissioning Traditional New Design Benefits iFix-based Alarm Generation PLC-based Alarm Generation More robust & reduce complexity Custom HMI design Rockwell GEMS library Amgen standard, Rockwell COTS support Win911 and HMI on common workstation HMI on Server Win911 on workstation Dedicated workstation for Alarm Notification Automation Hardware on business network (VLAN) Automation Hardware on Manufacturing Network Secure, dedicated network for automation assets limits exposure to threats Innovation and best practices helped drive our strategy
  11. 11. 11 CEMS Implementation • GMAX contract (i.e. T&M Not Too Exceed) • Competitively Bid • Leverage a Bundled Approach • Drive Savings Business Case Detailed Design Implementation /Testing Commissioning
  12. 12. 12 CEMS Implementation Business Case Detailed Design Implementation /Testing Commissioning • Leverage common documents for multiple buildings • URS, FS, NDS, OIDS • Generate site/building-specific documents • SDS, DT, IV/OV, RTM, VSR
  13. 13. Software Builds: CEMS Implementation
  14. 14. CEMS Implementation GEMS Library:
  15. 15. 15 CEMS Project Implementation Business Case Detailed Design Implementation /Testing Commissioning • Module Configuration Tool • Tag Rung Tool • Document Development Tool • Development Test in Parallel with live system • Development System on VM Environment • Mobile PLC for Parallel Communication
  16. 16. Module Configuration Tool: CEMS Project Implementation
  17. 17. Tag Rung Tool: CEMS Project Implementation
  18. 18. CEMS Project Implementation Document Development:
  19. 19. CEMS Project Implementation
  20. 20. 20 CEMS Implementation Business Case Detailed Design Implementation /Testing Commissioning • Software tools developed, translate design docs to commissioning docs • Minimal Validation Requirements • Minimal Downtime • I/O Wiring Conversion
  21. 21. I/O Wiring Conversion: CEMS Implementation
  22. 22. • What is Virtualization? 22 UCS Implementation
  23. 23. 23 • Benefits: • Less Physical Infrastructure to Maintain • High Application Availability • Stable System Modifications • Lifecycle costs • Risks: • Network Issues • Software/Application Compatibility • VMWare Robustness • Novel technology UCS Implementation
  24. 24. 24 UCS Implementation
  25. 25. Project Results • CEMS downtime required for startup 4 hours. • On time under budget for 8 consecutive startup scheduled 1 month apart • Solution can perform JackPanel functions with no invasive action • Automation solution is on a segregated Manufacturing Network • Maintenance cost reduced • 30% Cost Avoidance/Savings from Original Estimate
  26. 26. Questions? Tom Lopez, Amgen Richard Kleinfeld, M+W Automation
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 27 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you for attending our session!

×