Maintenance and calibrations
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Transcript of Maintenance and calibrations
© Bioproduction Group | www.bio-g.com 1/23/2014
Optimizing Maintenance and Calibrations
using Real-Time Scheduling
Jan 23, 2014
Rick Johnston, Ph.D. - Principal and Founder
Gary Wright - Senior Account Director, [email protected]
© Bioproduction Group | www.bio-g.com
Bioproduction Group
Founded in 2007 with an exclusive focus on
Biomanufacturing Operations
Primary goal of improving Quality,
Productivity, Flexibility and Operations in
Biomanufacturing
World Class “real time” data collection,
modeling, and simulation software
Technology Assisted
Knowledge Generation Tool
Specifically designed for the unique
needs of Analysts
Improving Quality, Productivity, Flexibility
and Operations at the World’s Largest
Biomanufacturers
© Bioproduction Group | www.bio-g.com
Bioproduction Group is now used by more than
20% of the world’s biomanufacturing capacity*.
0
5
10
15
20
25
2007 2008 2009 2010 2011 2012 2013
% o
f w
orl
dw
ide c
ap
acit
y*
Year
1/23/2014 2 * As measured by total installed production bioreactor volume.
© Bioproduction Group | www.bio-g.com
A collection of quotes*
1/23/2014 3 * Collected from 45 Bio-G phone interviews with biopharmaceutical
professionals from 16 companies, November 2012. Redacted for privacy.
Maintenance: “We got the OK, and turned
the power off. Turns out that also turned
off power to the skid in another part of the
facility, that was running a batch. Million
dollar mistake.”
Manufacturing: “Maintenance is always
trying to find out when equipment is
free… but to be honest we often don’t
know exactly ourselves.”
Manufacturing: “Calibrations? Mark does
that. It takes him about a week to find
places in the schedule where events will
fit. And every time we change our
schedule, he re-does his too. Patient
man.”
Maintenance: “I couldn’t count the number
of times I’ve gowned up, then found out
manufacturing will be using [the
equipment] till tomorrow. What a waste of
my day.” Manufacturing: “We tell our bosses we
schedule in SAP, but really? We use Excel
for detailed shop-floor scheduling.”
© Bioproduction Group | www.bio-g.com
Maintenance vs. Manufacturing
1/23/2014 4
© Bioproduction Group | www.bio-g.com
Scheduling Calibrations and Maintenance
is difficult
1/23/2014 5
Manufacturing
Maintenance / Calibrations
High Visibility
“Value Added”
Production Group
Low Visibility
“Necessary Evil”
Support Group
© Bioproduction Group | www.bio-g.com
Significant delays are introduced by
these events*
1/23/2014 6
Manufacturing
Calibrations
Maintenance Downtime
Overall fraction of time
scheduled for events * Bio-G internal data, sourced from representative
biopharmaceutical manufacturers. Exact numbers redacted.
Manufacturing
Calibrations
Maintenance
Downtime Delays
Observed time
required for events
© Bioproduction Group | www.bio-g.com
What causes these delays in
maintenance / calibrations?
Cause
"Equipmentunavailable"
"Manufacturing still inprocess"
"Maintenance tooklonger than expected"
"Co-ordination issues"
"Trained personnelnot present"
"Affects other part offacility"
1/23/2014 7
More than half of the reasons reported for delays were
due to poor scheduling or wrong information
Other
© Bioproduction Group | www.bio-g.com
Fundamental problem: two systems are
competing for one resource
CMMS Planning
Equipment
1/23/2014 8
Computerized Maintenance
Management Systems (CMMS)
Equipment Manufacturing Planning
Manufacturing Systems
CMMS systems and production systems can’t “see”
each other’s schedules
© Bioproduction Group | www.bio-g.com
For example: SAP*
1/23/2014 9
Plant Maintenance
Equipment Equipment Advanced Planning /
Optimization
* Bio-G is an SAP Certified Partner. Bio-G software is validated for use with SAP
Systems.
It is possible to schedule maintenance on a skid at the
same time that skid is being used for a process order
“Start calibration on
Chrom Col 1 at
2/1/2014 9:00am”
“Start downstream
Pro-A Cycling on
2/1/2014 12:00am” ???
© Bioproduction Group | www.bio-g.com
Need a scheduling “arbiter” that
prioritizes the finite resources
1/23/2014 10
Plant Maintenance
Equipment Equipment Advanced Planning /
Optimization
“Start calibration on
Chrom Col 1 at
2/1/2014 9:00am” “Start downstream
Pro-A Cycling on
2/1/2014 12:00am”
Finite Scheduler
“Start Pro-A on 2/1/2014,
then Calibration on
2/5/2014”
© Bioproduction Group | www.bio-g.com
Two Case Studies
1. “Simple Use” case study
– Take a plan (planned and production orders) from SAP and
schedule unit operations
– Take a schedule from a CMMS system and plan calibrations /
maintenance
– Publish that schedule out so it is visible
2. “Advanced Use” case study
– Use SAP for high level planning, but “blow out” a plan into
detailed production steps with work allocation
– Incorporate CMMS data (calibrations / maintenance)
– Allow users to publish and provide feedback on a schedule as it
is executed.
1/23/2014 11
© Bioproduction Group | www.bio-g.com
Case Study 1
• SAP APO used to generate initial planned and production orders with
proposed (earliest) start times
• A CMMS system used to generate equipment maintenance /
calibrations events
• Bio-G’s Real-Time Modeling System used as an ‘arbiter’ to schedule
the two
• Outputs are published to Microsoft Outlook, a video planning board,
back to SAP, and to Excel
1/23/2014 12
CMMS Planning
SAP
* Bio-G is an SAP Certified Partner. Bio-G software is validated for use
with SAP Systems.
Bio-G Real-Time
Modeling System
Excel (duplicate
current output)
Outlook
(calendar)
TV on shop floor
Demonstration
© Bioproduction Group | www.bio-g.com
Case Study: Takeaways
• Allows everyone to see an integrated view of the
manufacturing floor
– Different views for different groups (management, maintenance,
upstream, downstream)
– Incorporates both maintenance / calibrations and production plans while
optimally scheduling finite resources
• System is designed to be implemented in existing
enterprise architecture
– Supports most CMMS systems, SAP, DeltaV / Syncade, Rockwell
– No databases, “system administrators” or extensive training involved
– Less than one month setup and deployment (provided)
– Single person can run the system
– Can replicate current outputs, or provide “next generation” visualizations
like Outlook
• Supports “bring your own device” (BYOD)
– provided your corporate email is accessible from your email
1/23/2014 14
© Bioproduction Group | www.bio-g.com
Traditional Scheduling Software only
solves half the problem
1/23/2014 15
Planner
Creates
Schedule
Published
Schedule
Run Facility
Based on
Schedule
“How can planners see and respond quickly
to events on the manufacturing floor?”
© Bioproduction Group | www.bio-g.com
Bio-G’s software is designed to allow
real-time reaction to events
1/23/2014 16
Planner
Creates
Schedule
Published
Schedule
Run Facility
Based on
Schedule
Delays and
Rework
X Unexpected
Events
© Bioproduction Group | www.bio-g.com
Create / Update
Publish
Execute Observe
Reconcile
This feedback loop is designed to be
familiar to the user and real-time.
1/23/2014 17
Smart
Phones
iPads
Laptops
Rockwell /
DeltaV / OSISoft
PI Historians
Rockwell /
DeltaV / OSISoft
PI Historians
DeltaV +
OSISoft PI
Historians
© Bioproduction Group | www.bio-g.com
Case Study 2
• SAP and CMMS system as before
• Bio-G’s Real-Time Modeling System includes all of the detailed
manufacturing plan (down to detailed steps)
• Outputs are published to Microsoft Outlook, a video planning board,
back to SAP, and to Excel
• As the schedule executes, Outlook is used to communicate changes
back to the schedulers
1/23/2014 18
CMMS Planning
SAP
* Bio-G is an SAP Certified Partner. Bio-G software is validated for use
with SAP Systems.
Bio-G Real-Time
Modeling System
Excel (duplicate
current output)
Outlook
(calendar)
TV on shop floor
Two way integration
Demonstration
© Bioproduction Group | www.bio-g.com
Case Study: Takeaways
• Enterprise Ready
– Can be used by multiple people across the enterprise at the same time
– What if scenarios, testing
– User access control and other advanced features
– No database administrator or IT support required
• Allows a simple method of reconciling changes to schedules
– Delays, late starts, notes and other issues communicated to the
scheduler in real-time
– Allows real-time adjustments to the schedule (more than once a day!)
• System can model all the complexity of biotech
– Media and buffer prep, transfer panels and valve arrays
– WFI systems and Labor / shift structures
– Variability in processing times
1/23/2014 20
© Bioproduction Group | www.bio-g.com
Bio-G’s Technology Evaluation Program
• First three manufacturers who enroll in program are eligible
• Bio-G will setup the toolset
• Includes free 3 month evaluation
• 15 hours of consulting time with a Bio-G Engineer
– Set up of first model
– Training and Support to integrate with other data sources
• Free access to online training materials and the Bio-G wiki / help files
• Private WebEx demonstration for internal personnel
• Contact Gary Wright for more information
– 510-725-9875
1/23/2014 21
RTMS
Crosswalk
Q&A