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SIGMA, 고객의 생산성 향상 지원

FactoryTalk Historian과 FactoryTalk VantagePoint의 결합으로 제약 및 헬스케어 애플리케이션에서의 배치 및 프로세스 데이터 이슈 해결

과제

  • 생산 공정에 대한 가시성 확보로 적시에 적절한 대응 가능
  • 중앙화된 배치 보고와 생산 데이터의 장기적 아카이빙을 통해 기회 및 위협 파악
  • 이력 데이터에 대한 액세스 통제를 통해 적시 적소에 적절한 정보 제공

솔루션

결과

  • 고객에게 풍부한 데이터 세트 및 분석 기법의 혜택 제공
  • 제약 및 헬스케어 업계의 니즈에 맞게 간소화된 보고서 생성 및 배치 비교를 통해 이 기업은 전략 변화와 장기적인 여정을 위한 태세를 갖추었습니다.

Background

In the life sciences industry valuable data can be dispersed across multiple archives and systems. This presents issues for different users who have varying information requirements and require customised, contextualised yet comprehensive and coherent views of this data.

SIGMA, based in Goldbach and Marburg, Germany, a recognised Rockwell Automation system integrator, has developed a reporting toolkit based on FactoryTalk® Historian Site Edition (SE) and FactoryTalk® VantagePoint® EMI tailored to the needs of the pharmaceutical and healthcare manufacturers. The toolkit offers a configured set of reports, which can be used to analyse the information generated from various production processes and works with most automation solutions.

A German biotechnology centre – home to several innovative pharmaceutical companies – which, in the past, had completely relied on custom solutions from a third-party technology supplier, has now integrated this reporting toolkit into its existing production lines.

Challenge

Integrated historian software solutions are designed to collect and save process data. However, it is only when this data can be aggregated into meaningful reports that its true value becomes evident. It is only then that companies are in a position to compare production data and batch records, in order to improve not only the quality of their production, but also reduce reaction times in terms in response to changing market demands.

SIGMA has addressed these needs and has deployed just such a solution for the German biotechnology centre. The transition from basic process data capture to a configured data analysis solution now helps provide optimal data collection and collation.

“With process data capture being based on information from 3rd party PLCs and control systems, the challenge was getting effective access to alarms and events data from the existing fragmented database,” says Jochen Hasselbach Site Manager at SIGMA. “If this company could combine the process information with trending, alarms and events, it would improve productivity by eliminating friction points.”

Solution

FactoryTalk® Historian Site Edition offers high performance long-term archiving of production data. In conjunction with the web-based process visualisation available through VantagePoint EMI, the customer now has access to tailored report layouts and can display meaningful representations of this historical data. The report creation and batch comparison reporting toolkit also provides secure controlled access to historical data for a wide variety of access levels.

The SIGMA toolkit helps the customer to gather the dispersed production data and then present it in a coherent manner. OPC DA standard interfaces – distributed interface nodes (FTLD) – are installed as the software interfaces between the control system and Historian for local buffering of data on computers, which also control the production systems. Alarms and events are also archived in FactoryTalk Historian i.e. via OLE DB interfaces. FactoryTalk VantagePoint EMI then provides access to the production data and produces analyses and trends.

VantagePoint EMI can access a wide variety of platforms and data sources, such as Microsoft SQL Server or an Oracle database. The easy-to-use report creation toolkit brings in alarms and events, making it possible to show process information together with production information which would normally be hidden in the customer’s control system. This is the content that decision-makers need. “Extended batch-based data analysis functions and comprehensive web-based reporting help our customers to organise this information properly, making it useful and meaningful for a wide range of users at varying decisionmaking levels,” explains Harald Schmidt of Rockwell Automation.

Results

FactoryTalk Historian SE and FactoryTalk VantagePoint EMI are proven solutions in highly regulated environments such as life sciences and pharmaceutical industries. The described architecture can do more than just capture and visualise analogue data. Trending and analysis add-on tools can, for example, depict a trend in temperature in a batch and, at the same time, alarms and events highlight specific incidents. Each incident or process alarm at the customer is added to a notification list, which helps the operator to interpret the process.

The toolkit is capable of aggregating these alarms and events and displaying them in the same way as the control system itself. The information, which would otherwise only be available in the control system, is now available in the office environment. Furthermore they can be used for more expansive analyses – even combined with analogue values in one and the same trend.

포괄적인 인터페이스는 특정 수준의 제어 시스템 정보가 때로는 감춰진다는 것을 의미합니다. 그러나 이제는 이러한 정보들도 정상 수준 이상으로 공유될 수 있습니다. 예를 들어, 시그마는 고객의 제어 시스템에 있는 배치 보고 기능을 사용하며 이를 보강해줍니다. 결과적으로 고객은 현 공정을 참조가 되는 기준 배치의 샘플값과 실시간으로 자동 비교할 수 있게 되었습니다. 시스템 운전자는 현재의 공정 품질에 대한 직접적인 피드백을 수신하고 이에 따라 적절하게 대응할 수 있습니다.

 

조헨 하셀바흐는 "FactoryTalk VantagePoint EMI가 제공하는 것처럼 프로세스 데이터를 웹 페이지 형태로 가시화하는 것은 기술 사용자는 물론 비기술 사용자에게도 고유한 혜택을 제공한다"며, "이는 사용자 교육에 필요한 시간을 획기적으로 감소시켜 주며, 기술이나 전문 분야가 다른 여러 사용자가 포털을 운영할 수 있다"고 설명합니다. 간단하게 드래그 앤 드롭하여 비교할 여러 배치를 선택할 수 있습니다. 실질적인 데이터 분석은 확대, 형태 및 룰러 등 사용자가 이미 익숙한 표준 툴들을 사용해 수행되며 이벤트는 플롯 영역에 데이터 세트로 표시됩니다. 이 툴킷은 분석에 사용될 수 있는 여러 표준 보고서를 제공하여 고객이 통합 보고 툴을 사용해 결과를 평가 및 배포할 수 있도록 해줍니다.

The availability, processing and comparison of process data from the control system delivers multiple forms of flexible analytical reporting suitable for the respective industry. With the solution provided by Rockwell Automation and SIGMA, it is very easy to combine process data with trending, alarms and events, and analyse this crucial data at all levels in order to help towards greater productivity.

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