AP08 - Eli Lilly Extends Visibility, Improves Life Cycle Management
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Transcript of AP08 - Eli Lilly Extends Visibility, Improves Life Cycle Management
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
Eli Lilly Extends Visibility, Improves Life Cycle Management
Mirih Shah
Principal Controls Engineer
Eli Lilly and Company
About Lilly Corp & Branchburg
Eli Lilly Corporate:
• Based in Indianapolis, Ind.
– Fortune 500 Company
– In business 135+ years (Founded by Colonel Eli Lilly: May, 1876)
– Three core values: Integrity, Excellence, Respect for People
– One of top 10 biopharmaceutical companies
– 38,000+ Employees
– Operations in more than 40+ Countries
Branchburg, NJ:
• Formerly ImClone Systems
• Primary Manufacturing Location for monoclonal antibodies
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 3
Building 50 Operations
• Overview of manufacturing operations and
terminology
– Two manufacturing suites with space for a third
– Primary focus on Biopharma products
– State-of-Art biopharmaceutical manufacturing facility
• Commercial Products
– ERBITUX®
– Cyramza™
• Multiple Clinical Development Products
– 8MW solar field supplies over 50% of BB50’s needs
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 5
About Mihir
• 18+ years of experience in management, design & implementation of diverse automation control applications.
• Worked with MNCs in Pharmaceutical, Water, Chemical, Tire, Printing Press, Cement, Paper, Iron sheet galvanizing, and Textile Industry.
• Experience with Rockwell Automation®, Modicon & Siemen’s automation products
• Worked as Rockwell Automation® GTS engineer in India
• 10 years with Eli Lilly & Company
• Bachelor degree from India; MS in Project Management from Stevens; Six Sigma Green Belt certified
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 6
Process Control System
Migration Project Objective
• Needed to upgrade to contemporary (x64) Operating
Systems
• Justified Project
– Improve Life-Cycle Management
• Mitigate Risks within the Production Environment
• Fault-Tolerance/Recovery
• Improved Change Management (support rolling upgrades)
– Provide Visualization outside the suite
– Robust data collection
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 7
Project Approach
• Approach – 3 phases driven by ops schedule, engineering effort
• Architecture – FactoryTalk® Application Definition & Software Component Placement
• Multiple Applications
• Historian
– Virtualization (who would implement) • VMware: FactoryTalk® View SE, FactoryTalk® Alarms and Events, FactoryTalk®
Directory, RSLinx® Enterprise, FactoryTalk® Transaction Manager & FactoryTalk® Historian Site Edition Server & Remote HMI Clients
• Thin Manager: Plant floor Clients
– HMI Clients • Thin Manager (Bricks)
• Computers running VMware Client
– Development & Testing • Deployment of a Simulation environment including Network Infrastructure, Servers,
HMIs and PLCs
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 8
Project Approach
• Architecture (Continued)
– Expanded Visualization • Scenarios: Remote, Mobile, Support
– Alarming • HMI or FactoryTalk Alarms and Events
– Win911
– Network hardware • Enterprise Multi-Layer Switches
• Firewall
• Stakeholders – Core teams: AEG, IT, Process Engineering, Manufacturing,
Validation, QA
– Team members: ~12 (100% time) + ~10 (20-40% time)
– Roles defines based on area of expertise – Developer, IT, process SME, Validation, Quality Control,
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 9
Process Control System
Prior to Migration
• PCS based on ControlLogix® & RSView®32
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 10
Process Network Communication Flow
PCN Level-2
DMZ Level-3
Lilly Network Level-4
FTD for Hist & AC
Server: MS Reporting Services, Application for event data entry
Server: FTTM- MSSQL Database:
(Events, Alarms, CIP & Batch reports),
Reporting services, Automatic print out
Corporate Users
Area PLCs Skids PLCs
BRICK - FTVSE Area CLIENTS
Server: FT Historian SE-
PI Database
Thin Manager Secondary
Thin Manager Primary
VDIs for Areas View Only SE
Clients
VDIs for Skids View Only
SE Clients
BRICK – FTVSE Skid Client
VMWare Gateway for SE Clients and Station
- Skid flow path - Area flow path
- Historian flow path
RDS Servers for Area SE Clients
RDS Servers for Skid SE Clients
Corporate Users: SE View Only Clients – Laptop/ iPad
Skid – FTVSE + RSLinx Ent.
FTD for each Suite Skids
FTD for each Suite
Area: FTVSE svr Primary
Area: FTVSE svr Secondary
Server: MSTS – Process
Book, Excel
RSLinx Ent.-1, ICU-1, Primary
RSLinx Ent.-2, ICU-2, Secondary
PLCs Level-1
RSLinx Ent.-1, ICU-1, Primary
RSLinx Ent.-2, ICU-2, Secondary
Project Benefits (Results)
• Improved reliability due to Redundant Server/Client HMI
applications
• Reduced Time to recover Operator workstation
• Management remote access for status & troubleshooting
information
• Engineer & IT remote access for troubleshooting
• Reduced time to calibrate instrumentation
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 14
Visualization Access Enhancements
• Plant Floor
– ACP Thin Manager • RDS/Bricks for HMI clients
• Fault tolerance Clients
• Shadowing for troubleshooting
• Minimize hardware replacement time
• Corporate Users
– VMware View • View only client applications for live process status &
troubleshooting
• Same rights for users on process & corporate n/w
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 15
Data Collection Enhancements
• Transactional Data Collection – FactoryTalk Transaction Manager (~5K tags)
• Alarms & Event
• CIP & Batch
• Manual data entry
• Continuous Data Collection – FactoryTalk Historian ME (~800 tags)
• Bioreactors, CIP Skids, Area Applications
– FactoryTalk Historian SE (~2-3K tags) • Data through Redundant RSLinx® Enterprise & ICUs
• Site Repository Feed by Historian ME
• Plant floor & corporate users’ secure access
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 16
Challenges
• Defining scope for IT involvement
• Determining best tools for HMI software delivery
• FactoryTalk Application configuration (Data Servers)
• Alarming Configuration
• Project schedule shortened
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 17
Future / Next-Steps
• Suite 1 upgrade (Phase-2)
• FactoryTalk Historian SE (PI) Batch implementation
• Reports in FactoryTalk VantagePoint
6/2/2015 Company Confidential ©2015 Eli Lilly and Company 18
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
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