Brandon Henning, Steven Lichon Rockwell Automation Pharma ... · PDF file• Dashboards &...

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Rockwell Automation Process Solutions User Group (PSUG)November 14-15, 2011Chicago, IL

Overviews- CPG Suite- Pharma SuiteBrandon Henning, Steven LichonRockwell Automation

Pharma Suite



CPG Suite Overview

Brandon Henning,Rockwell Automation

CPG Suite Overview

• Brandon Henning – CPG Suite Product Manager, Rockwell Automation• Business / Technical Challenge:

– Assist our customers in enhancing their automation investment to solve key industry challenges

• Achieve Operational Excellence• Improve Supply Chain Effectiveness• Delivery Product Safety and Compliance• Support Sustainable Manufacturing

• We are achieving this by delivering a module based MES solution specifically for CPG customer

– Production Management– Material Management– Quality Management– Performance Management– CPG Suite Integration Gateway


ERP & Supply chain triggers

Portal partsand content

Manufacturing derived KPIs

Production and Process data

HMI

ERP/MRPBusiness Intelligence

CPG Suite Architecture

ProductionCentre

Automation Systems Batch Systems

Operator Dashboard

Manager/Engineer Dashboard

Business User

Copyright © 2011 Rockwell Automation, Inc. All rights reserved

Production Management Application

• Process Order Management– Make & Packaging Process Order Management– Create new, edit, cancel Process Orders– Process Order Status (Scheduled, Pending, Ready, Running,

Completed, Canceled)– Dispatch Process Orders to a production area

• Product Management – Product Definition– BOM – Ingredient and QTY – Materials, Equipment and parameters– Consumables and Productions– Define capacity limits

• Process Order Execution– Process Sequence Enforcement– Manage steps in Process Sequence (Manual or automatic)– Manage Order Status (update, paused, completed, cancel)– Collecting Process Parameter Data (start, stop, pH, brix, etc)– Consumption and Production messages

• Control Layer Integration– Pre-defined UDT for ease of integration and messaging

• ERP Integration Gateway Messages– Production Order Messages– Operations Status Messages– Operations Completion Messages

• Production Management Reports– Genealogy Report (limited)– Process Order History– Process Unit History– WIP Labeling


Key values:• Increase First Pass Yield up to 10%• Reduce Overtime up to 15%• Increase On Time Delivery up to 20%• Improve Right First Time up to 15%

Material Management Application

• Materials Management Activities– Material Definition– Liquid & Dry material management– Carrier Management (fixed or Mobile)– WIP Material Identification

• Material Management Execution– Transfer, adjust, scrap, rework, merge, split, receive,

ship (auto & manual) – Minor Ingredient Kitting– Rework & Scrap Handling– Status of WIP Inventory (blocked, quarantined,

released) • Dashboards & Reports

– Inventory Status (WIP, Scrap) Qty, level & location– Storage Unit Inventory (adjustments, additions)– Mobile Vessel Report (where its been and states)

• Business System Integration– Material Movements– Material Disposition

Key values:• Reduce safety stock up to 10%• Reduce cycle counting up to 50%• Track raw, WIP and finished goods

inventory• Improve identification and labeling of

materials


Quality Management Application

• Quality Test Definition– Instruction / Information, – Digital Control– Multistate control– Analog Control– Comparison control– Deviation control– Foreign Body Ejection Monitoring control

• Quality Test Execution– Process Control Setup - Conditions for test– Procedural process -how to do the test– Schedule – When to do the test

• Sample Management– Planned and Unplanned– Collect in-line or batch quality data– Collect equipment status, alarm & event data

• QA Release Control (WIP Hold, FG release)• Dashboards & Reports


Key values:• Improve First Pass Quality up to 12%• Reduce Quality Compliance Costs by as

much as 80%• Cut Quality Exceptions by up to 50%• Reduce Brand Risk

Performance Management Application

• Performance Monitoring– Process Order Management & Planning– Downtime event collection– Monitoring of plant bottleneck assets

• Performance Review– Pre-configured KPI dashboards & reports– OEE

• Performance Analyze– A platform for continuous improvement– Drill-down into KPI’s to indicate root cause

• Architecture– Pre-configured, out of the box capability– No customization necessary– Access via Internet Explorer– Includes Datamart, Analytic Engine & KPI

Dashboard

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 8

Key values:• Continuous Improvement Platform• Increase production capacity• Reduce manufacturing costs• Defer capital expense• Eliminate transcription errors

Integration Gateway

• Plug & Play Enterprise Service Bus/SOA Connectivity

– Though there is no dependency, it is possible to take advantage of existing ESB technology

• Event-Driven Messaging– Changes in one system automatically trigger

notification to the other system– Keeps systems synchronized in real-time

• Flexibility, Scalability, and Highly Availability– Guarantee of message delivery regardless of

network outages and other anomalies– Bi-directional, highly available architecture– Can be configured to handle multiple instances of

SAP, multiple instances of FTPC, or both• Designed for rapid deployment

– Easy modification/creation of integration scenarios

• Out of the box support for common touch points with SAP

– Download Process Orders– Download Material Master– Download Process Bill of Material– Download Batches & Sublots – Upload Material Produced– Upload Material Consumed


Key values:• Enhances investments in ERP• Completes the Manufacturing

Supply Chain • Reduces raw material inventory• Out of the Box capability• Fast time to value, lower TCO



PharmaSuiteOverview

Steven Lichon,Rockwell Automation

Pharma Suite

PharmaSuite Overview

• Steven Lichon – Information Solutions Business Consultant• Business / Technical Challenge:

– Improve the effectiveness of manufacturing:• Recipe Author• Operator• Reviewer

• System Evolution– Role Based by Design– Ease of Integration– Open Content


PharmaSuite Overview (cont.)

• Benefits– Eliminates paper from the shop-floor– Drastically reduces time and effort to define master batch records– Decreases complexity and volume of master batch records– Reduces operator errors– Provides a complete and correct batch documentation– Improved batch review cycle time– Less costly and time-consuming investigations for deviations– Whatever information you may want is at your fingertips– “Review by exception" or “Real time release” principles can be applied to EBR


The Value of

Pharma Suite• Role based by design

• Ease of integration

• Open content

Improve the effectiveness of …

Operator

Approver

Author

Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 13

Process Design

Recipe Design

Dispatching

Recipe Execution

Review/Approval

Analyses

Faster turn around times = Speed = Benefit

Recipe Life Cycle

Process Design

Recipe Design

Dispatching

Recipe Execution

Review/Approval

Analyses

Batch Record Review

EBR Execution

Recipe Designer

Process Design

Recipe Design

Dispatching

Recipe Execution

Review/Approval

Analyses

Recipe Life Cycle – Optimizing

• Role-based by design– Graphical recipe workbench– Re-usable recipe building blocks– Flexible configuration of UI– Review and approval of recipes

• Ease of integration– S88-aligned master recipes– Support of S95

• Open content– SDK for 3rd-party building blocks

Recipe Designer

16Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Focus on time to recipe – Dedicated to support recipe authors

• Role-based by design– Intuitive and consistent UI– System drives operator– 2D Barcode support– Exception management

• Ease of integration– Real-time equipment integration– S88-aligned control recipe

• Open content– 3rd-party building blocks– Extensibility of workflows

Recipe Execution


Focus on operator efficiency –100% support of the operator’s main workflow!


Cockpit – easy access to• Workflows• Parallel operations• Exceptions • Alams & Events

Navigator – easy access to• History of all phases• Detailed execution information• Additional functions

Recipe Execution

• Role-based by design– Review by exception– Quality dashboard– Workflow-driven review process

• Ease of integration– S88-aligned Batch Record– B2MML (XML)-based reporting– Link Historian and LIMS

• Open content– Seamless integration of 3rd-party building blocks

Review & Approval


Focus on batch review cycle time – Full support of “Review–by–Exception”

• New usability concepts based on your input and our expertise

Speed up your recipe life cycle

Ease of integration

Role based by design

• Ease of integration of FT Pharma Suite into IT landscapes based on close alignment with industry standards

Accelerate integration

Open content• Unique method to extend the capabilities of FT Pharma Suite

Accelerate deployment

High Level Summary



Pharma Suite

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Brandon Henning, Steven Lichon Rockwell Automation Pharma ... · PDF file• Dashboards &...

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