© Process Analysis & Automation 2005 Short Course “I want to Automate that Process” Malcolm...

Short CourseShort Course

“I want to Automate that Process”

Malcolm Crook

Key questionsKey questions

• Where do you want to automate ?• Why do you want to automate ?• What do you want to automate ?• How do you want to automate ?• When do you want to automate ?

Course contentsCourse contents

• Choice of method

• Choice of equipment

• Choice of robot or stacker

• Choice of scheduler (pre-emptive/real-time)

• Automated method design

• Documentation of projects

– URS FDS FATs SATs

• Data handling

WhereWhere do you want to automate ? do you want to automate ?

• Location• Access• Floor• Facilities

– Compressed air– Vacuum– Power– IT Network access

WhyWhy do you want to automate ? do you want to automate ?

• Increased throughput• Improved data quality• Plate tracking• Sample identification• Reduced analysis cost• Safety

HowHow do you want to automate ? do you want to automate ?

• partial automation• complete automation• definition of success• data handling• integrator

Golden Rules of AutomationGolden Rules of Automation

If it doesn’t work manually …

… it won’t work more efficiently, if you automate it!

Just because it works manually …

… doesn't mean it will work, if you automate it!

IntegrationIntegration

Automated systems have to be build and integrated • DIY• Single provider• Independent integrator

WhenWhen do you want to automate ? do you want to automate ?

• All at once• Step by step

WhatWhat do you want to automate ? do you want to automate ?

• Small– instrument only connections– no robots– Stacker versus laboratory robot

• Medium– workcells– small static robots

• Large– systems, distributed processing– tracked robots

Choice of equipmentChoice of equipment

Usually• decided by the science• methods have been decided• equipment has been decided• automating a manual method

Choice of automationChoice of automation

• Budget• No of pieces of equipment• Reliability• Safety• Laboratory space

Choice of robot or stackerChoice of robot or stacker

• Types– Stackers– Laboratory robot– Factory robot

• Every integrator has a favourite• Most customers have favourites

StackersStackers

Positives• Commercially available• 1-2 instrument access

Negatives• Poor data handling• 1-2 instrument access

Best system• OVERLORD • Stacker• instrument

Stacker exampleStacker example

• OVERLORD™• RapidPlate• GE LEADseeker• Barcode reader• Data handling• Plate tracking

Laboratory robotsLaboratory robots

Positives• Small• Versatile• Safe

Negatives• reliability

Laboratory robotsLaboratory robots

Factory robotsFactory robots

Positives• Accurate• Reliable

Negatives• Needs screening

Factory robotsFactory robots

Small automated systemsSmall automated systems

• Small– instrument only connections– no robots

• Analysis or sample preparation method• Devices to undertake method• System consists of

PCsoftware to control the system

Medium automated systemsMedium automated systems

• Medium– workcells– small static robots– <= 5 instruments

• load and unload operations• plate reader• plate washer• diluter• System consists of

PCsoftware to control the systemrobot stack & instrument

instrumentrobot

stacks

Low volume dispenserLow volume dispenser

High resolution plate readerHigh resolution plate reader

Microscopy systemMicroscopy system

Pipetting stationPipetting station

High Volume DispenserHigh Volume Dispenser

Large automated systemsLarge automated systems

• Large– distributed processing– unipoint robot– tracked robots– multiple workcell tracked system

Multiple work cell tracked systemMultiple work cell tracked system

EnclosuresEnclosures

Why do you need ?• Safety• Protect experiment• Key access

Options• Extraction system

Choice of schedulerChoice of scheduler

• pre-emptive• real-time

Scheduling - Pre-emptiveScheduling - Pre-emptive

• Pre-emptive– static– run optimised before equipment moves– simple to set up– not good on error recovery or flexibility

Scheduling - real timeScheduling - real time

• Real-time– flexible– good at error recovery– poor on MULTIPLE key timings

e.g Incubations, Shaking

Automated method designAutomated method design

• Sub divide process into logical steps• Have one global routine• Teach all the robot moves as

– “get …” and “put …”• Combine routines to make sub units

– “load plate reader and run method”

Interfacing to LIMS & data sourcesInterfacing to LIMS & data sources

• LIMS is a mature market• the main problem is data acquisition• most LIMS offer data collection from single instruments• most data sources

– high data throughput– complex robotic systems

• need to offer more comprehensive interface to LIMS

Current IntegrationCurrent Integration

Laboratory Information Management System

Instruments

Automated workcellsInstrumentsInstruments

Target TopographyTarget Topography

What is the Integration LayerWhat is the Integration Layer

Automated workcellsInstruments

Integration layer

What is the Integration LayerWhat is the Integration Layer

Automated workcellsInstruments

OVERLORD™

How OVERLORD can be used in the How OVERLORD can be used in the Integration LayerIntegration Layer

OVERLORD has• choice of external calling protocols• full file reading ability

– text file/csv– Microsoft Access– SQL

• ability to control most instruments• ability to control most automated workcells

CommunicationCommunication

• Indirect – A CSV file is used to exchange data • Direct – OVERLORD interfaces directly to LIMS

– e.g Use ODBC

Indirect CommunicationIndirect Communication

ADVANTAGES

• All LIMS can communicate using CSV Files

• Easy to integrate

DISADVANTAGES

• Error handling is poor in an Automated System

• Limited Data Exchange

Direct CommunicationDirect Communication

ADVANTAGES

• Integration is more efficient• Access more data• Error Recovery

DISADVANTAGES

• More time needed to set up the integration

• Greater understanding of the LIMS required

Which integration method is best?Which integration method is best?

• Depends on volume of data and type of data

• Use Indirect if….– low data exchange– data is only being ‘pushed’

• Use Direct if….– great level of data exchanged– Automated system runs off the data from LIMS

Documentation of projectsDocumentation of projects

• Why document ?• User Requirement Specification (URS)• Functional Design Specification (FDS)• Factory Acceptance Tests (FATs)• Site Acceptance Tests (SATs)

User Requirement Specification (URS)User Requirement Specification (URS)

• Tell a supplier what you want

• Instrument choices• Full methods• Throughput• Data handling• Aspirations

Functional Design Specification (FDS)Functional Design Specification (FDS)

• Get what you want

• Full details of how URS will be achieved

• Signed agreement point

Factory Acceptance Tests (FATs)Factory Acceptance Tests (FATs)

• See what you want exists

• Demonstration of an agreed set up of tests• Usually down with water

– Sign each test as completed

Site Acceptance Tests (SATs)Site Acceptance Tests (SATs)

• Receive what you want

• Retest some or all of the FDS test• Run with real materials• Sign each test as completed

In summary ...In summary ...

The key points are:• Decide what you want to do very carefully• Plan plan and plan again• Write a detailed URS• Engage a suitable integrator• Follow the project• Stay involved• Be prepared to learn

© Process Analysis & Automation 2005 Short Course “I want to Automate that Process” Malcolm...

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