Maintenance and calibrations

© Bioproduction Group | www.bio-g.com
1/23/2014
Optimizing Maintenance and Calibrations using Real-Time Scheduling
Jan 23, 2014
Rick Johnston, Ph.D. - Principal and Founder
Gary Wright - Senior Account Director, gwright@bio-g.com

Bioproduction Group
Founded in 2007 with an exclusive focus on Biomanufacturing Operations
Primary goal of improving Quality, Productivity, Flexibility and Operations in Biomanufacturing
World Class “real time” data collection, modeling, and simulation software
Technology Assisted
Knowledge Generation Tool
Specifically designed for the unique
needs of Analysts
Improving Quality, Productivity, Flexibility and Operations at the World’s Largest Biomanufacturers

Bioproduction Group is now used by more than 20% of the world’s biomanufacturing capacity*.
0
5
10
15
20
25
2007
2008
2009
2010
2011
2012
2013
% of worldwide capacity*
Year
1/23/2014
2
* As measured by total installed production bioreactor volume.

A collection of quotes*
1/23/2014
3
* Collected from 45 Bio-G phone interviews with biopharmaceutical professionals from 16 companies, November 2012. Redacted for privacy.
Maintenance: “We got the OK, and turned the power off. Turns out that also turned off power to the skid in another part of the facility, that was running a batch. Million dollar mistake.”
Manufacturing: “Maintenance is always trying to find out when equipment is free… but to be honest we often don’t know exactly ourselves.”
Manufacturing: “Calibrations? Mark does that. It takes him about a week to find places in the schedule where events will fit. And every time we change our schedule, he re-does his too. Patient man.”
Maintenance: “I couldn’t count the number of times I’ve gowned up, then found out manufacturing will be using [the equipment] till tomorrow. What a waste of my day.”
Manufacturing: “We tell our bosses we schedule in SAP, but really? We use Excel for detailed shop-floor scheduling.”

Maintenance vs. Manufacturing
1/23/2014
4

Scheduling Calibrations and Maintenance is difficult
1/23/2014
5
Manufacturing
Maintenance / Calibrations
High Visibility
“Value Added”
Production Group
Low Visibility
“Necessary Evil”
Support Group

Significant delays are introduced by these events*
1/23/2014
6
Manufacturing
Calibrations
Maintenance
Downtime
Overall fraction of time scheduled for events
* Bio-G internal data, sourced from representative biopharmaceutical manufacturers. Exact numbers redacted.
Manufacturing
Calibrations
Maintenance
Downtime
Delays
Observed time required for events

What causes these delays in maintenance / calibrations?
Cause
"Equipment
unavailable"
"Manufacturing still in
process"
"Maintenance took
longer than expected"
"Co-ordination issues"
"Trained personnel
not present"
"Affects other part of
facility"
1/23/2014
7
More than half of the reasons reported for delays were due to poor scheduling or wrong information
Other

Fundamental problem: two systems are competing for one resource
CMMS Planning
1/23/2014
8
Computerized Maintenance Management Systems (CMMS)
Equipment
Manufacturing Planning
Manufacturing Systems
CMMS systems and production systems can’t “see” each other’s schedules

For example: SAP*
1/23/2014
9
Plant Maintenance
Equipment
Equipment
Advanced Planning / Optimization
* Bio-G is an SAP Certified Partner. Bio-G software is validated for use with SAP Systems.
It is possible to schedule maintenance on a skid at the same time that skid is being used for a process order
“Start calibration on Chrom Col 1 at 2/1/2014 9:00am”
“Start downstream Pro-A Cycling on 2/1/2014 12:00am”
???

Need a scheduling “arbiter” that prioritizes the finite resources
1/23/2014
10
Plant Maintenance
Equipment
Equipment
Advanced Planning / Optimization
“Start calibration on Chrom Col 1 at 2/1/2014 9:00am”
“Start downstream Pro-A Cycling on 2/1/2014 12:00am”
Finite Scheduler
“Start Pro-A on 2/1/2014, then Calibration on 2/5/2014”

Two Case Studies
1.“Simple Use” case study
–Take a plan (planned and production orders) from SAP and schedule unit operations
–Take a schedule from a CMMS system and plan calibrations / maintenance
–Publish that schedule out so it is visible
2.“Advanced Use” case study
–Use SAP for high level planning, but “blow out” a plan into detailed production steps with work allocation
–Incorporate CMMS data (calibrations / maintenance)
–Allow users to publish and provide feedback on a schedule as it is executed.
1/23/2014
11

Case Study 1
•SAP APO used to generate initial planned and production orders with proposed (earliest) start times
•A CMMS system used to generate equipment maintenance / calibrations events
•Bio-G’s Real-Time Modeling System used as an ‘arbiter’ to schedule the two
•Outputs are published to Microsoft Outlook, a video planning board, back to SAP, and to Excel
1/23/2014
12
CMMS Planning
SAP
Bio-G Real-Time Modeling System
Excel (duplicate current output)
Outlook (calendar)
TV on shop floor

Case Study: Takeaways
•Allows everyone to see an integrated view of the manufacturing floor
–Different views for different groups (management, maintenance, upstream, downstream)
–Incorporates both maintenance / calibrations and production plans while optimally scheduling finite resources
•System is designed to be implemented in existing enterprise architecture
–Supports most CMMS systems, SAP, DeltaV / Syncade, Rockwell
–No databases, “system administrators” or extensive training involved
–Less than one month setup and deployment (provided)
–Single person can run the system
–Can replicate current outputs, or provide “next generation” visualizations like Outlook
•Supports “bring your own device” (BYOD)
–provided your corporate email is accessible from your email
1/23/2014
14

Traditional Scheduling Software only solves half the problem
1/23/2014
15
Planner Creates Schedule
Published Schedule
Run Facility Based on Schedule
“How can planners see and respond quickly to events on the manufacturing floor?”

Bio-G’s software is designed to allow real-time reaction to events
1/23/2014
16
Planner Creates Schedule
Published Schedule
Run Facility Based on Schedule
Delays and Rework
X
Unexpected Events

Create / Update
Publish
Execute
Observe
Reconcile
This feedback loop is designed to be familiar to the user and real-time.
1/23/2014
17
Smart Phones
iPads
Laptops
Rockwell / DeltaV / OSISoft PI Historians
Rockwell / DeltaV / OSISoft PI Historians
DeltaV + OSISoft PI Historians

Case Study 2
•SAP and CMMS system as before
•Bio-G’s Real-Time Modeling System includes all of the detailed manufacturing plan (down to detailed steps)
•Outputs are published to Microsoft Outlook, a video planning board, back to SAP, and to Excel
•As the schedule executes, Outlook is used to communicate changes back to the schedulers
1/23/2014
18
CMMS Planning
SAP
Bio-G Real-Time Modeling System
Excel (duplicate current output)
Outlook (calendar)
TV on shop floor
Two way integration

Case Study: Takeaways
•Enterprise Ready
–Can be used by multiple people across the enterprise at the same time
–What if scenarios, testing
–User access control and other advanced features
–No database administrator or IT support required
•Allows a simple method of reconciling changes to schedules
–Delays, late starts, notes and other issues communicated to the scheduler in real-time
–Allows real-time adjustments to the schedule (more than once a day!)
•System can model all the complexity of biotech
–Media and buffer prep, transfer panels and valve arrays
–WFI systems and Labor / shift structures
–Variability in processing times
1/23/2014
20

Bio-G’s Technology Evaluation Program
•First three manufacturers who enroll in program are eligible
•Bio-G will setup the toolset
•Includes free 3 month evaluation
•15 hours of consulting time with a Bio-G Engineer
–Set up of first model
–Training and Support to integrate with other data sources
•Free access to online training materials and the Bio-G wiki / help files
•Private WebEx demonstration for internal personnel
•Contact Gary Wright for more information
–gwright@bio-g.com
–510-725-9875
1/23/2014
21
RTMS
Crosswalk

Maintenance and calibrations

Recommended

Recommended

More Related Content

Similar to Maintenance and calibrations

Similar to Maintenance and calibrations (20)

More from GBX Summits

More from GBX Summits (20)

Recently uploaded

Recently uploaded (20)

Maintenance and calibrations