A global pharmaceutical company needed a engineering study and impact gap assessment for a new facility. Partnered with Enterprise
Partners assessing gaps with scheduling, planning, engineering designs, specifications, vendors and physical systems with readiness to install, commission, and
validate (IQ, OQ, PQ) the new $168 M facility. Assessed gaps and alignments between corporate, applications, and the new facility with IT, operations and
process owners against schedule, resources, and cost with the manufacturing, lab, warehouse, packaging and serialization.
Formulation, Spray Drying, Vacuum Drying, Formulation Hydration, Sterile Filtration, Component Prep Wash (Autoclaves), Vial
Filling Line, Freeze Drying, Vial Inspection, EMS Monitoring, Building Management (HVAC/AHU), Solid Dose Packaging, Vial Packaging Line, Dispensing and
Sampling, Process Utilities (Air, Water, Gas, Solvents), Server Rooms, Networking, and Lab Systems (Autoclaves, Dryers, PLC's, Incubators, HPLC, Chambers,
Study included meetings with multiple groups and teams (VP's, sr. managers, directors, and team leads). Analyzed scheduling, operations,
business processes, specifications, equipment, IT, electrical, networking designs, and roadmaps. Systems included IT networking, server room (30 server
virtuals), Oracle EBS, Maximo, Labwatch, Rockwell FactoryTalk & View, OSI-PI, iFix, BMS, Labwatch, LDAS, LES/LEN, Log Books, OBIEE, SysTech, Belimed, GEA,
NNE, and Ulhmann Packaging.
Delivered results with report-out, gap assessment presentation, opportunity savings, application road maps and commission and testing
readiness to the executive steering committee.
Food Plant ISA-88 Recipe Batch and Control Management
Automated two food plants with dressing and ingredient products to increase productivity and profitability while maintain quality control
to meet FDA title 21 and ISO-9001 compliance. The goal was to optimize batch processes, eliminate unplanned and reduce cycle times minimizing change over
times, and remove capacity bottlenecks in the batch and packaging processes while reducing cycle/down time and operations and maintenance costs.
Process equipment consisted of two batch production lines merged with different routes fed from 8 raw material storage tanks,
mixing units, blenders, batching unit tanks with transfer pumping with VFD controls, weigh scales, postion control valves, closed loop cooling
exchangers, surge tanks, filling and capping, labeling, case packaging and robotic palletizers.
The solution provided a ISA-95/88 architecture with a plant netowrk, Wonderware SCADA distributed 8 operation stations in batch process
cells. Engineering and configuration included two EWS stations, batch server and Rockwell Allen Bradley Control Logix and PAC controllers with PID loops, and
I/O System with 10K points managing 750+ Recipes, recipe process simulation, 95 phases and over 255 devices. System connected to a AS-400 Business System and
MES system tracking production orders, material consumption, reporting, work-instructions, metrics, ingredients, mixing, lab sampling and product
The solutions increased production capacity by 50% resulting (100 batches/day - 65.5M
lbs./year) with an estimated $9 millions cost
savings over 2 years. Cost savings resulted in reducing formulation costs, batch cycle times and conversion costs. The solution was easy to use for operations
producing consistent product quality deferring capital investment through increased customer orders and plant capacity.
Food Plant Products, Materials and Operations Traceability
A food company with several plants in the mid west to southern states specializing in broths, fats and protein ingredients partnered
to find a better solution to improve its process, operations and technology to support increasing demand with its customers and value chain.
One plant lacked visibility and automation across it's processes to track lot product and compliance while another plant automated with Rockwell
Factory Talk needed MES capability with lots, traceability, OEE and downtime with its processes and equipment. Product specifications, lab inspections, and
cooking processes needed to be integrated into the lab with product pack out providing a smart manufacturing informational model to support product runs, FDA
compliance, BRC standards and traceability.
Process equipment consisted Griders, Separators (Weight), Box Dryers, Dehydrated Dryers, Frozen Broth Freezers, Fluid Bed Dryers, Cooking
Broth Room (8 Broth Cookers), and Packout (Dry Meat, Broths).
The solution provided a ISA-95 manufacturing enterprise architecture with a plant network, budgets for controls and plant wide network to
their PLC's tracking the customer order, product Sku, materials and process conversion steps and parameters with genealogy and traceability through cooking
processes and product specifications through pack out giving visibility of resources, scheduling, allocations and assets.
The prject savings estimated was $3.5 million using the plants labor rates with multiple benefits increasing product, metrics and
operations visibility with OEE, SPC, product specs and lab quality traceability. Over a $1 M in savings could be achieved eliminating manual processes, data
entry, accuracy, downtime, and scheduling resources. Additional $882 K in savings could be realized with 45% more capacity throughput recovering $1.92 M lbs.
in lost product managing equipment constraints and resource scheduling with CIP and equipment asset downtime.