Manufacturing Execution & Information Management System

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Manufacturing Execution & Information Management System

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  • 06/07/09 14:53 © 2007 Microsoft Corporation. All rights reserved. Microsoft, Windows, Windows Vista and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries. The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation. MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.
  • Manufacturing Execution & Information Management System

    1. 1. Manufacturing Execution & Information Management System Hi-Coater, Sugar-Coating & Granulation Suites Wyeth Consumer Healthcare Guayama, Puerto Rico
    2. 2. <ul><li>Primary requirement to upgrade non-21CFR Part 11 Compliant Control System </li></ul><ul><li>System could only be run in manual mode </li></ul><ul><li>Lack of configuration options limited number of products that could be processed without generating many nuisance alarms </li></ul><ul><li>Batch Reporting & Recipe Management Solution was an outmoded MS Excel application </li></ul><ul><li>PLC Application had many problems that needed to be resolved to allow automatic operations </li></ul>
    3. 3. <ul><li>Critical operations require Electronic Signatures </li></ul><ul><li>Original system provided only a single “text-based” local batch report </li></ul><ul><li>Lacking History & Audit Trail Reports: Audit Trail, Login History, Alarm History </li></ul><ul><li>Trending Application was difficult to navigate and had no context to batches & steps </li></ul><ul><li>Batch investigations were very difficult to perform due to data stored in multiple, disconnected locations – much of the data is paper-based </li></ul>
    4. 4. <ul><li>Upgraded 10+ year old FIX32 application to the latest version of GE FANUC’s iFIX Product </li></ul>Control System Area <ul><li>Multi-Pane </li></ul><ul><ul><li>Critical Alarm Area </li></ul></ul><ul><ul><li>Warning Alarms </li></ul></ul><ul><ul><li>Real-Time & Historical </li></ul></ul><ul><ul><li>Trending </li></ul></ul>
    5. 5. <ul><li>Centralized Security to Corporate Domain Controller – No Local User Account Harmonization process required </li></ul>Domain Security controls application access and electronic signatures for performing critical operations acknowledging alarms, starting/ending batches, recipe mods, etc.
    6. 6. <ul><li>Integrated fully relational, enterprise S88 Recipe Management System with full Revision Management Support </li></ul><ul><li>S88 Relational Recipe </li></ul><ul><li>Management System </li></ul><ul><li>Download Recipes to PLC at start of batch, then PLC can execute entire batch disconnected from network </li></ul><ul><li>Easily compare recipe revisions to determine effects of changes on manufacturing system </li></ul><ul><li>Recipe Data tied back to Historical Trending Solutions </li></ul>
    7. 7. <ul><li>Integrated Work-Instructions guide operators through complex processes – with Video Augmentation </li></ul><ul><li>Fully integrated work instructions starts moving the paper-based batch record to a fully electronic format </li></ul><ul><li>Integrates with SCADA/HMI Solution </li></ul><ul><li>Videos can be included in the Instruction to visually demonstrate complex processes </li></ul><ul><li>Multi-Lingual Supported </li></ul>
    8. 8. <ul><li>Utilizing Business Objects Crystal Reports linked to RDBMS to create dynamic batch and production reports </li></ul><ul><li>Fully Integrated Batch Reporting from RDBMS </li></ul><ul><li>Navigate Reports using Batch Number or by Date/Time </li></ul><ul><li>Incorporate complex trending directly into “Extended” QA Batch Reports </li></ul><ul><li>Speeds batch release times and MIR studies </li></ul><ul><li>Improves & Enhances process understanding efforts </li></ul>
    9. 9. <ul><li>Combine Historian & Relational Data for an unprecedented view of historical data </li></ul>Combine Relational Data with Process Historian Data Overlay Recipe Steps over Trend Data and zoom to each process step Inlet & Exhaust Temperature Trends for a single Batch Right-Click on Trend to Navigate by Batch
    10. 10. <ul><li>Integrate Alarms & Events directly with Trend Data to demonstrate their effect on critical process parameters </li></ul>Combine Relational Data with Process Historian Data <ul><li>View all Critical Alarms or Audit Trails for displayed time period </li></ul>Inlet & Exhaust Temperature Trends for a single Batch (with Critical Alarms) <ul><li>Click on trends to reveal additional information </li></ul><ul><li>Icons show where critical alarms occur </li></ul>
    11. 11. <ul><li>Integrate S88 Recipe Model with Process Historian </li></ul>Inlet & Exhaust Temperature Trends for a single Batch (with Recipe Parameters) Combine Recipe Configuration with Historian Data to better understand your processes <ul><li>Recipe Parameters for each step </li></ul><ul><li>Easily navigate between Process Steps </li></ul>
    12. 12. <ul><li>Compare Batches – see how processes change over time </li></ul>Inlet & Exhaust Temperature Trends for a two Batches (Spraying Cycle Displayed) Batch Compare allows you to compare a known good batch (Golden Master) against any other – by Time or Process Step <ul><li>Batch Time & Alarm/Event Compare Statistics </li></ul><ul><li>Compare same or different parameters </li></ul>
    13. 13. <ul><li>View trend data that includes product sampling information from PAT sources such as NIR </li></ul>PAT Product Sampling trended against Batch Air Temperature Trends (Good for demonstrating how various parameters affect product output) PAT Product Sampling trended against Batch Nozzle Pressure Trends PAT Data Critical Process Data
    14. 14. <ul><li>Integrate Batch Duration Compare Reporting to quickly isolate problematic batches </li></ul>Batch Time Compare Batch Time Compare (with Step Times) Compare Batch & Step Times (Longer Batches/Steps can be an indicator of problems that occur during batch execution). Good way to start the batch investigation process.
    15. 15. <ul><li>Integrate Alarm Frequency “ Batch Compare ” Reporting to pinpoint problems between batches </li></ul>Compare Batch & Step Alarm Counts (a greater number of alarms that occur during a batch or process step can be a good indicator of a problem batch or recipe configuration) Batch Alarms Compare (total alarms for each batch) Batch Alarms Compare (with # of Alarms per Process Step)
    16. 16. <ul><li>Alarm Frequency Reports demonstrate which alarms are causing the most down-time (and costing the most) </li></ul>Great for controlling batch costs, these reports direct maintenance personnel to target problematic equipment and processes to keep systems running as efficiently as possible. Also a good way for Technology Specialists to optimize recipes and reduce recurring costly batch delays. Alarm Frequency Report (which alarms occur most often over time) Alarm Time-To-Resolve Report (which alarms take the longest to resolve)
    17. 17. <ul><li>Alarm Frequency Reports can be used to target specific shifts or even personnel at the root of the alarms </li></ul>Alarm Frequency by Shift Assess your Training Efforts and Programs with Shift/Operator-specific Alarm Frequency Reports Alarm Frequency by specific Operators Alarm Frequency by Month
    18. 18. <ul><li>Simplified “1-Server” architecture makes information visible from anywhere inside the plant (plant-floor) and across the Intranet and Internet as well (if so desired) </li></ul>Integrated Information Dashboard

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