Company insight
Empowered workforce Fixed screens aren’t practical in a facility of the future. Workers need tablets or mobile screens to carry with them as they follow production from one area to another. Thin client technology makes mobile visualisation possible. And it can help to reduce human errors when using mobile equipment.
Thin client technology uses software to centrally configure and deliver content to visualisation sources like mobile devices. Some thin client software platforms have location-based content delivery to mobile devices. This is critical in the facility of the future. Why? Because it allows operators to only access screens and applications in physical areas where they’re working.
process and interact with it using voice commands and gestures.
Compliance driven
Smaller batch sizes and faster changeovers may seem challenging given today’s compliance burdens. But the right manufacturing execution system (MES) can help your facility of the future be both agile and compliant.
An integrated MES that automates tasks, collects data in-process and delivers analytics can provide relief from lengthy compliance activities. In fact, instead of weeks of review, your facility of the future can achieve real-time release without quarantining product. What should you look for in an MES? Make sure it can
“The facility of the future is optimised to help biotech manufacturers compete tomorrow. But it’s already being proven around the world today.”
For example, an operator standing in front of a mixing tank can receive control of it from the software. But if they walk away, they will only retain visualisation of the tank. They can’t control it. This can keep the operator informed of how the asset is running and help to reduce the risk of erroneous operation. Additionally, as training resources are tightened, visualisation technologies like AR can help. Training workers in an AR environment allows them to learn about and interact with production assets without disrupting production. If equipment fails, a technician can access diagnostics and work instructions in an AR environment to get it back up and running faster.
AR can also be using during operation to improve compliance. Operators in the facility of the future using smart glasses with AR could see an overlay of the single-use tubing connections in their field of vision. Instead of looking at a work instruction and trying to determine connection points, the connection points would illuminate as the operator looked at the equipment with the glasses. And the software would verify that the tubing connections are correct prior to allowing the system to move to the next step. Additionally, smart glasses could allow the operator to dynamically follow the
seamlessly integrate from your ERP system to your plant floor. It should also have these key attributes: ■
An electronic batch record (EBR) capability that collects product genealogy, uses review by exception and connects with your serialisation system.
■ ■
Role-based recipe management that optimises each stage of a recipe life- cycle, from creation to qualification.
Data-integrity features to help prevent documentation or human errors that can result in wasted product, contamination or recalls.
One manufacturer recently proved the power of MES in one of its facilities. The company developed a new approach to making an in-demand drug. It included using an MES that digitised paper records and automated document management. By making production 100% paperless, the company reduced the risk of human error, like incorrect data entry. The company also calculated it would save 5–10% on labour costs by eliminating manual data recording. A more efficient batch review process is expected to reduce supervisory and QA batch product review by up to 75% and cut management review cycle time by 50%. In addition to an MES, scalable analytics tools can also help you improve
World Pharmaceutical Frontiers /
www.worldpharmaceuticals.net
your performance while achieving compliance. These tools collect raw data from a variety of sources and turn it into useful information to drive better decisions from the edge to the enterprise. For example, a single processing line or inspection system can produce multiple terabytes of data daily. Extracting insights like temperature deviations and refrigeration exposure times from this data can help you minimise how long batches are held.
Securing a smarter facility The facility of the future reimagines production to create a tremendous competitive advantage. But its more connected nature requires that you make security a priority. Your security approach must go beyond traditional IT systems or an industrial DMZ. You need to address risk across an attack continuum. Where do you start? Consider building your security strategy around the five functions of the NIST Cybersecurity Framework. As NIST puts it, these functions “represent the five primary pillars for a successful and holistic cybersecurity programme”. They can also prepare you for the global security requirements in IEC 62443. The five functions include: ■
Identify: understand your attack surface and asset vulnerabilities.
■ ■ ■ ■
Protect: implement measures to safeguard your control systems.
Detect: vigilantly monitor risks and detect when threats bypass your protection measures.
Respond: develop a plan to immediately respond to security incidents and minimise damage.
Recover: quickly recover and return to production with root-cause incident investigation to follow.
The facility of tomorrow, today The facility of the future is optimised to help biotech manufacturers compete tomorrow. But it’s already being proven around the world today. The right design approach – one that’s built for seamless connectivity and fluid information and that uses mobile equipment, single-use technologies and a modern DCS – can help you quickly deploy this game-changing facility. ●
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