Control System Modernisation in the Life Sciences Industry
Enhanced capability of a modern automation system ensures consistent, fully documented and optimised flexible manufacturing processes
Enhanced capability of a modern automation system ensures consistent, fully documented and optimised flexible manufacturing processes
Ageing control technology can prevent consistent, fully documented and optimised production. By modernising your control systems and manufacturing software you can eliminate operator interventions that introduce variability and extensive documentation; enable efficient and compliant, fully automated electronic record keeping; and simplify system maintenance and standardisation across your facilities.
Modernising your control system with Emerson’s DeltaV™ distributed control system and software applications ensures quality, compliance and optimised production. By coordinating sophisticated operations across the plant and eliminating islands of automation, DeltaV helps to remove production variability and improve data management. Utilising batch, mobility, simulation, spectral process analysis, engineering and diagnostics software, life science companies can establish consistent, validated and fully documented production.
DeltaV Batch software supports flexible manufacturing and increased production speed, while reducing engineering time and validation. DeltaV Batch is based on the ISA88 Batch Standard and is a 21 CRF (Code of Federal Requirements) Part 11 compliant solution that provides fully automated electronic batch record keeping. This streamlines the audit trail and enables Good Manufacturing Practices (cGMP) to be easily achieved. Improved traceability and enhanced compliance are enabled through stored historical data, automatic batch and process event capture and system configuration. DeltaV Batch also facilitates easy integration and standardisation on a single control system architecture for the entire plant, helping to provide access to real-time, meaningful data while reducing overall costs.
DeltaV Mobile Worker technology further increases workforce efficiency and productivity by supporting flexible, mobile working. Easy-to-use state-of-the-art operator interfaces dynamically present the data you need, anywhere and anytime you need it. Real-time process data is easily accessible to operators while on the plant floor via tablet or handheld devices, helping them make faster actionable decisions. Operators can perform process procedures and record observations directly into the system, thereby avoiding transcription errors.
With online DeltaV Batch Analytics, a multi-variate analysis of your process is performed based on models generated from a compilation of historical batches. Faults in your batch process are detected and identified in real time, enabling operators to take corrective action before a negative impact on production occurs. This results in decreased costs, reduced cycle times, increased yield, reduced waste, reduced variability and improved reliability.
Lab testing for quality validation can create delays of days, weeks or even months. DeltaV Spectral Process Analytic Technology (PAT) helps to avoid this by adding real-time spectral analysis to the control system. DeltaV Spectral PAT uses modern machine learning algorithms and embedded chemometric models to accurately predict product quality and reduce variability in real time. By implementing in-line, real-time, continuous, closed-loop process verification and control, life science manufacturers can gain better regulatory management, while optimising facility performance and throughput.
Emerson has extensive control system modernisation experience, supporting migrations from all types of legacy systems. Experienced project engineers and established processes, together with artificial intelligence and machine learning tools are available to assess the state of your automation, quantify operational benefits, then plan and execute your project. With over 5,000 project resources worldwide, your control system modernisation can be executed flawlessly, on schedule, with minimal production impact.
Emerson provides a faster and easier pathway to replace your legacy control system. DeltaV IO.CONNECT makes the transition possible without the need to completely overhaul the existing automation equipment infrastructure. With no rip-and-replace required, this helps to preserve the existing IO infrastructure investment and simplify migration in gradual manageable steps. This reduces project risk and minimises interruption to manufacturing.
