Travis Cox from Inductive Automation explains how to reduce human error in GMP by automating data capture from PLCs and devices on your plant floor, consolidating it, and feeding it into centralized analytics & reporting for profound business intelligence.

1. Beyond Compliance
Reducing Human Error in GMP
with Automation

2. The Sponsor
✔
✔
✔
Plant Management Platform
BEYOND COMPLIANCE

3. About the Presenter
BEYOND COMPLIANCE
Aaron Bolshaw
VP of Marketing
Travis Cox
Co-Director of Sales Engineering
● Experience with HMI (Human
Machine Interfaces) and SCADA
(Supervisory Control and Data
Acquisition) projects
● Former Director of Training

4. Before we get started
BEYOND COMPLIANCE
Helpful tips
✔ Informal, conversational approach
✔ Ask Questions (Q&A at end)
✔ Only panelists are displayed/heard
✔ Recording link will be shared
✔ Slides will also be shared
✔ Audio issues? Use call-in number

5. About Inductive Automation
About Inductive Automation
• Founded in 2003
• Founded by experienced system integrator
• HMI, SCADA, MES, and IIoT software
• Highly diversified customer base across many industries
• Over 2,200 integrators
• Used by 48% of Fortune 100 companies
Learn more at: inductiveautomation.com/about
Our mission is to create industrial software that empowers our customers to swiftly
turn great ideas into reality by removing all technological and economic obstacles.

6. Ignition: Industrial Application Platform
One Universal Platform for
SCADA, MES & IIoT
• Unlimited licensing model
• Cross-platform compatibility
• Supports containers
• Based on IT-standard technologies
• Scalable server-client architecture
• Web-managed
• Web-launched on desktop or mobile
• Modular configurability

7. Reducing Human Error In GMP Manufacturing
• People Are Human
• The Blame Approach
• How Can We Improve?
• Tips to Reduce Human Error
• Digitize & Reduce Manual Work
• Capture More Data
• Apply High Performance Techniques
• Get Data to More People
• Q&A
Today’s Agenda:

8. People Are Human
People Make Mistakes Because They Can
• Most systems do not directly consider human
error prevention as part of the design
• Human error is complex
• Accounts for nearly ¼ of all unplanned
downtime
• Costs manufacturers millions
• Attention, memory, alertness, illness, stress,
and fatigue all trigger GMP violations, hurting
quality and wreaking havoc with compliance

9. The Blame Approach – Not Helpful
Failure To Understand Human Error
• Companies still frequently fail to substantively
and correctly address human errors
• Typical response is retraining
• Leads to less trust
• Management is less aware of system
weaknesses
• Requires systemic view

10. How Can We Improve?
Evaluate Everything
• Management Systems
• Procedures
• Interactions
• Human Factors Engineering
• Training
• Immediate Supervision
• Communication
• Individual Performance

11. Tips to Reduce Human Error
1. Digitize & Reduce
Manual Work;
Connect Systems
and Remove Data
Solos
2. Capture More
Data
3. Apply High
Performance
Techniques
4. Get Data to
More People

12. 1. Digitize and Reduce Manual Work

13. Remove Silos of Data
HMI / SCADA
MES /
Quality
Maintenance
Management
ERP
No Connectivity
Between Systems

14. Connect Everything Together
Touch
Panels
Databases
PCs
Mobile
Devices
PLCs
LIMs
MES, QMS & ERP
Systems
Web
Services
MQTT
OPC UA, OPC DA,
OPC Tunneller
Cloud
Services
Your System
Connection Hub

15. Reduce Manual Work
Streamline Processes
• Eliminate whiteboards and clipboards
• Eliminate personnel transferring data
from one system to another
• Capture data automatically
• Integrate with ERP, QMS, MES, or other
business applications
• Create heads-up displays
• Leverage RFID, badges, and barcode
scanning

16. 2. Capture More Data

17. Legacy HMI/SCADA System Architecture

18. Conventional Architecture

19. Access to Real-Time Data / Application
See and Control Your Process Anywhere
• Most important aspect
• On-premise, remote, over VPN
• Plant floor, office, home, remote
• Access on any device
• PC, Panel PC, TV, smartphone, tablet, etc.
• No installation
• No restoring backups
• No licensing

20. Implement an MQTT Architecture

21. MQTT Architecture

22. Add Edge Computing
Advantages of Edge
• Poll data at the source
• Poll at faster rates
• Get access to more data
• Efficiently provide data to
infrastructure
• Add computing at the source
(machine learning)
• More security
• True scalability

23. Edge Computing Architecture

24. Add New Sensors
Opportunities with New
Sensors
• Capture more I/O data
• Overlay onto existing network
• Connect to infrastructure
• Wireless technology
• Cost effective
• No PLCs
• No running conduit or power
• Plug and play
• Leverages MQTT

25. Example: Add Sensors to Detect Downtime Reason
Eliminate Manual Downtime Entry
• Accurately capture downtime event (start
time and end time)
• Get to root cause faster
• Eliminate operators entering downtime
manually
• Entering wrong times or duration
• Selecting incorrect reason
• Operators will gain more context and gain
more confidence
• Focus on getting production running again

26. POLL
What best describes your plant’s GMP maturity level?

27. 3. Apply High Performance Techniques

28. High Performance Focus
Making the Best Possible Tool for the Operator
• Turn data into information
• Draw attention to the most important information
• Add more context
• Reduce reaction time

29. High Performance Focus
Example: Analog vs. Digital Watches

30. High Performance Focus
Example: Blood Pressure Reading

31. High Performance HMI
Sparkline
Redundant
Coding
Moving
Analog
Indicator
Use of
Color

32. 4. Get Data to More People

33. Leverage Modern Browsers
Access Anywhere
• Leverage HTML5 & CSS3
• High level of security
• Run anywhere
• No plugins, native
• Modern browsers (Chrome, Firefox, Safari,
Edge)
• Phones & tablets (iOS, Android)
• Harness power of mobile device
• Send secure web links
• Familiar experience (Google Drive,
Microsoft Office 365, AWS, etc.)

34. Enhance Security
Modern Cyber Security Protocols &
Infrastructure
• Tried and true standards
• HTTPS / TLS
• Role and zone-based security
• Auditing
• Centralize identity management
• Industry leading encryption protocols
• SAML, OpenID Connect
• Integration with 2FA systems
• Extra layer, verify identity of users
• Use existing corporate credentials
• Supported by IT

35. Cost Savings with Connected Devices & Sensors
BEYOND COMPLIANCE
● Human error causes nearly 1/4 of all unplanned downtime in manufacturing -> expensive
● The fewer touches, the better
○ workers displaced by automated data capture can be reassigned to higher value-added
activities
● Sensors & devices less expensive to add than you think
○ many affordable alternatives
● Centralized reporting enables fact-based, on-the-spot decision-making and analysis

36. Q&A
BEYOND COMPLIANCE

37. Resources
White Papers & Surveys
Webinars & Videos
Product & Partner Info
Solution Consultation
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