Customer Use Case: Audit Trail Data From 100 Devices Across 8 Manufacturing Areas
Data integrity plays a critical role for any life science manufacturer, so imagine having to collect and discern audit data from almost 100 devices across eight manufacturing areas. It’s nearly impossible to generate audit trails on all the various devices with different HMIs and islands of information everywhere.
Solve Your Compliance Vulnerability Issues With Informetric Systems’ InfoBatch® InfoETL Apperture Solutions has partnered with Informetric Systems to provide an advanced technology solution that can:
Accommodate disparate and, frequently, siloed data
Remove the entire human data collection and analysis headache
Automate and streamline the entire process
Eliminate data integrity vulnerabilities
Include reporting and routing for electronic approval
Be GMP-compliant
Save Time & Money
by eliminating human data collection
Eliminate Audit Trail Vulnerabilities
with a secure, automated solution for collection and reporting
Gain GMP-Compliance Confidence
with access to comprehensive, reliable audit trails
Learn More About the Data Integrity Benefits of InfoETL
Address Your Cybersecurity Challenges and Concerns
Accomplish a culture of cybersecurity through a combination of technologies, strategies, and processes. Our assessment is an integral part of the continuous improvement process that comprises a sound cybersecurity program. We start by identifying risks and areas for improvement. Then we use network monitoring tools to identify real vulnerabilities, provide tactical recommendations, and create a roadmap for remediation.
Our advanced cybersecurity assessment measures practices and procedures against the industry standard, NIST SP800-82, to identify, protect/detect, respond, recover, and govern your organization’s cybersecurity risk. As part of our advanced assessment, we’ll also create an inventory of your OT assets.
Meeting the challenges of improving unit operations requires the use of OT data that spans multiple departments. Apperture’s Data Workshop is an ideal way to get to the most impactful use cases, quickly. We start by getting the right people in the room, diving into pain points, finding symptoms of variability, and then discussing how your data can drive analytics use cases. Armed with a sound plan, our team leverages a self-service analytics platform called Seeq. The Seeq platform is designed to work with your tribal knowledge of the process and leverages the power of connecting disparate data sources.
Data Analytics Workshop Addresses Big Challenges
Our data workshop is designed to address big, overall objectives, including:
Production yield
Production capacity
Production schedule adherence
Unplanned downtime
Equipment performance
Overall Equipment Effectiveness
Apperture ensures success throughout your data analytics journey by developing a strong relationship with your team. Using our Data Workshop format, we learn where we can complement your talent and drive the most impactful goals.
Start your Data Analytics journey more quickly using Seeq and the data analytics experts at Apperture Solutions. We can drastically cut down the amount of time spent fixing time-series data so you can spend more time coming up with brilliant ideas of solving problems faster.
Alarm Management is a timely topic for any process control manufacturer whose operators are inundated with alarm flooding, or who is looking to adopt an alarm rationalization strategy. At Apperture, we work with paper mills, chemical plants, life sciences companies, specialty chemical, nuclear facilities, and the mining/processing industry, so we have a breadth of experience to tap into, state-of-the-art tools to support our recommendations, and the experts to ensure that our customers experience a successful outcome.
Many companies upgrade to more current levels of their DCS for a variety of reasons—to take advantage of more features and modern technologies, as well as better integration and reporting. As part of this manufacturer’s migration journey, their alarm management data carried forward, but since it previously had not been part of an overall alarm philosophy, there was too much data and little prioritization of alarms. This impaired the operators from effectively and consistently responding; therefore, they needed to adopt a rationalization approach. The goal was to adopt a process that would allow them to move closer to the ISA standard, especially since many of their long-term operators (who had ‘tribal knowledge’) were retiring. Newly hired operators could not only benefit from this approach—but also needed adequate training to fully apply these new technologies, stay compliant, and ensure safety.
“Working with Apperture on Alarm Rationalization has been transformational in the sense that we now have our team focused on the alerts that they need to address, rather than be de-sensitized to what is happening.” – Operations Manager
AgileOps™ Operations Management Software was our technology of choice for our client. The software is designed to assist with the process of alarm rationalization—the systematic review and optimization of alarm systems to enhance their effectiveness, reduce alarm fatigue, and improve overall plant safety and efficiency—as well as move them toward the highly desirable ISA 18.2 standard. This software also ensures that our client gets the most value out of the alarm management system because every alarm is actionable; the alarm system loses its appeal when an operator wastes time sifting through nuisance alarms.
The objectives of their program were to:
Prevent (and eliminate where possible) alarm floods that can overwhelm operators
Increase operator effectiveness, by rationalizing meaningful, relevant, and actionable alarms, eliminating ‘bad actors’ (excessive alarms), and conditionalizing alarm logic
Incorporate state-based alarming, allowing them to dynamically manage alarms relative to a state change in the process
Focus on critical issues, ensuring that operators are alerted to those issues requiring immediate attention
Reduce downtime and maintenance costs
Stay compliant with standards and regulations—ensuring the safety of their people and equipment, as well as the community and environment
To address the training issue, Mimic™ Simulation Software allows us to create a real-time, dynamic simulation of plant behaviors, enabling new operators to gain hands-on experience in a controlled environment. Simulation technologies, such as Mimic, empower industrial manufacturers to mitigate the impact of the knowledge gap resulting from the aging workforce, upskill the current workforce, and ensure the continuity of operations and expertise in the long term. This program takes the operators through fifteen different exercises based on actual events—each one demonstrating a real issue they could potentially face in the field.
In the future, our client is considering replacing much of their current training with Digital Twin technology, as well as creating a larger-scale training program across the facility. Mimic can provide that capability, giving them industry exercises in the actual environment where they’ll be running a process.
Apperture Production Optimization Services
We offer a wide range of services to improve process performance and efficiency:
Planning, dynamically managing, and consistently measuring equipment utilization
Architecting and implementing strategies that deliver optimal control, reducing variability and minimizing disruptions and abnormal situations
Enriching the operator environment through digital simulation and assessment tools, while defining a work environment suitable to today’s technologies
Apperture Managed Services
Our Managed Services professionals are an extension of your team—focused on improving operations and lowering costs by minimizing process downtime and risk. That’s why we focus on your objectives, your timetable, your ability to do the work and get trained, and your organization’s appetite for change.
*Sources: ASM Consortium; World Oil, Economic Benefits of Training
CONNECT WITH US
Take the next step to adopt best-in-class tools and techniques to reap the benefits of Industry 4.0.
Apperture Solutions is thrilled to be attending the upcoming ISPE-CaSA Tech Show on Wednesday, February 28th at the Raleigh Convention Center. We invite you to stop by booth #617 to engage with our Life Sciences consultants about the benefits of integrating silos of data across your organization and transforming that data into actionable information. Our goal is to build bridges across the network to get the right information to the right people and transform your business towards greater efficiency, productivity, and success!
Visit us at booth #617 to learn more about our capabilities and solutions.
Cutting-Edge Data Analytics
Discover how our advanced data analytics tools can unlock hidden insights within your operational data. Our consultants will demonstrate how our solutions empower you to make data-driven decisions that drive efficiency and productivity.
Batch Quality Prediction Example: Delayed lab results make it difficult to optimize input of the process to control the batch yield. By creating an on-line model for yield based upon concentration, volume, and temperature, in near real-time, customers have realized millions in cost savings through rapid identification and root cause analyses of abnormal batches.
Streamlined Operations Management
Learn about our comprehensive operations management solutions designed to optimize your processes from end to end. From inventory management to supply chain optimization, our experts will showcase how we can streamline your operations for maximum performance.
Digital Work Instructions: As production processes become more complex and experienced, plant operators retire and customers struggle to train new operators. Our process experts can define efficient work processes and convert them into digital instructions to guide new operators through their process workflow, using computer vision and dynamic interfaces to alert operators if tasks are performed incorrectly and guide them to do the job right the first time.
Alarm Management: Critical for Safety and Efficiency
In the era of pneumatic controls, alarms were few and costly. Today, alarms are essentially ‘free’ with an unintended consequence of overuse. This can hinder an operator’s ability to respond to abnormal conditions effectively. Operators often mute speakers to deal with constant interruptions, important alerts go unnoticed, and potential disasters become a looming threat.
With technology advancing and systems growing increasingly complex, effective alarm management is imperative for safety, efficiency, and maintaining order in the digital world.
Alarm Philosophy serves as the cornerstone of the ISA 18.2 Standard. It calls for the creation and upkeep of a guiding document that meticulously outlines the purpose, objectives, roles, responsibilities, and overall strategy concerning alarms. This document acts as the North Star, providing clarity and direction. The Alarm Philosophy establishes a system for prioritizing alarms and includes guidelines for commissioning alarms to ensure seamless integration into the existing system. It also covers training requirements for personnel handling alarms, ensuring proficiency and safety.
Let Apperture be your partner at every stage of your alarm management journey.
It may be time to take an honest inventory of your organization’s skills, technology capabilities, and operational certainty. Our Managed Services professionals can be an extension of your team—focused on improving operations and lowering costs by minimizing process downtime and risk. That’s why we focus on your objectives, your timetable, your ability to do the work and get trained, and your organization’s appetite for change.
Technology Does Not Stand Still, Nor Should We…Or You
We speak your language—regardless of your process or platform—and we understand your challenges. We listen, ask the right questions, then apply best in class solutions to meet your challenges, based on our team of hands-on, experienced engineers and solutions consultants.
“I get the most satisfaction from customer enablement—understanding my customers, interpreting their needs, and applying advanced technologies for their benefit. I appreciate the opportunity to explain the amazing tools they have today and how best to leverage them to gain even more value in the near term.” Learn more about Boyd.
“As one of our MES Practice Leaders, I spend my days deeply embedded in my specialty, but I’m also aware that while many of our customers are familiar with the terminology, they do not necessarily know where to start to solve their manufacturing challenges. I hope to pique your interest by addressing some of the most commonly asked questions about MES…in a brief, easy-to-understand manner.”
What Value Can an MES Bring to Any (and Every) Manufacturing Organization?
Manufacturing Execution Systems (MES) provide governance of the manual activities that are part of a process manufacturing facility. While automation is certainly a part of most process industries, many manufactured products are produced with steps or tasks performed by humans, as well. There are a number of reasons for this: sites that make many products, making it difficult to automate; products that require ‘in-process’ verifications; and products with variable inputs. This is true for most industries—from pharmaceuticals to battery production to yogurt. Wherever steps are performed without automation, it’s the job of someone in a quality-focused role to question all that can possibly go wrong. Did they use the right materials? Did we establish the required accountability for the production steps? Were the materials in good condition (spoiled milk is still milk)?
Ultimately, the manufacturer has to prove that they produce something consistently—so the customer/consumer has less need to test it and is more confident when they buy it. Quality issues can impact price, involve health or safety questions, and in general, impact the business. The integrity of the manufacturing data is critical—and MES drives that integrity. MES systems can also help lay the ‘data foundation’ for a manufacturing dashboard to help discover and address other manufacturing deficiencies, such as excess hold times.
Who Uses MES Systems?
Many industries use MES systems—they can be either discrete or process manufacturers. The requirements of the MES system are different for each and are often served by different vendors. Discrete manufacturing can be thought of as something like an assembly process. For example, a car needs to be assembled with all of the correct parts (SUV fenders do NOT go on a sedan), all of the parts of a particular model need to be assembled the correct way, and the result is a finite number of sellable units.
Process manufacturing is something that cannot be taken apart or sold in different quantities. Whether you are manufacturing food, paint, or pharmaceuticals, the materials/ingredients have to be mixed, reacted, heated/cooled, and ‘processed’ according to a very specific recipe, with a list of input ingredients. Within process manufacturing, MES systems are most common in processes that make ‘batches’ of product and where there are more manual steps. The need for certainty of the repeatability aspect makes it almost a requirement in pharmaceuticals and biotech, but there is growing demand in the chemical and food industries, as well.
All of this information is integrated with company business systems to support those in supply chain, finance, and quality—who drive orders into the MES and get data back—helping them understand the amount of material in production, produced, and collected as scrap material, for instance.
You are invited to a day of knowledge-sharing sessions with Apperture, Emerson, and R.E. Mason life sciences experts. This workshop is ideal for operations management professionals, as well as those involved with technology transfer & commercialization, data management & visualization, process development, and manufacturing intelligence & analytics. Download flyer to view agenda.
When:
Wednesday, August 30th 10:00AM – 4:30PM (lunch, open house, & networking)
