Workflow Automation as an - MESA · PDF file• Motivates standardization. ... –...

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Copyright 2011 MESA North American Conference

Workflow Automation as an alternative to Traditional MES

Jay MellenEVP Business Development

Savigent Software

Chuck RedpathDirector of IT

The HallStar Company

Copyright 2011 MESA North American Conference

Defining Workflow Automation• Manufacturing environment

comprised of systems, equipment and people, unified by processSystems

Equipment People

Process

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Defining Workflow Automation• Workflow Automation

provides a controlled system for processes

• Provides the ability to migrate paper based processes to managed workflows

• Workflows detect relevant events and manage responses while generating meaningful manufacturing intelligence

Systems

Equipment People

Systemfor

Processes

Paper BasedProcesses

ManagedWorkflows

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Range of Applications• Workflow Automation is

execution centric as opposed to database centric in nature

• Any functionality in “traditional software” can be provided by systems of workflows

• Resulting systems are very configurable, flexible and robust

• Workflow execution covers the full range of needs from:

– Manual (people driven) to automated– Active (controlling) to passive

(monitoring and collecting data)

StandardOperations

ExceptionManagement

MOM/MESSystem

CAPASystem

EquipmentOCAPs

APC/FDCController

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Key Benefits and ConsiderationsConsiderationsBenefits

• Guarantees compliance and execution

• Provides unparalleled levels of traceability

• Improves operational efficiency

• Yields significant manufacturing intelligence

• Motivates standardization

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Key Benefits and ConsiderationsConsiderations• Open architecture and

connectivity• Service Oriented Architecture

(SOA)• Composite application

development• Event driven• Flexible, extendible and

configurable• Accessible

Benefits• Guarantees compliance and

execution• Provides unparalleled levels

of traceability• Improves operational

efficiency• Yields significant

manufacturing intelligence• Motivates standardization

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HallStar

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Introduction to Hallstar• Experts in Ester Chemistry for Polymer Additives and

Personal Care Ingredients• Enviable Patent Estate

– 100+ patented extensions around the world• Newly Patented Technologies

– Photostability/sunscreen formulations• Green Chemistry/Biopolymer Formulations• PARAPLEX® Approach - proprietary molecular

design system • Provide Customized Solutions

Markets Served

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Polymer Additives Personal Care% of Revenue

Hallstar Customers• Customers are prominent global players in the

polymer and personal care industries spanning more than 50 countries

• Diverse customer base– 2200 + active purchasing locations, many of which

are distributors with many more customers– Multiple year relationships

• Most products are proprietary and customers are typically reluctant to switch products and suppliers – Require consistent high-quality products and solutions

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Hallstar Manufacturing Operations

• Production assets in 3 locations in the U.S.• Primary facility in Chicago, IL.• 30 year-old facility• Chemical Batch Process Manufacturing

– Combine reactants in premix operations– Heat to cause a chemical reaction in reactor– Perform finishing operations in finishing tank– Cool and move to storage or other packaging

Hallstar Systems and Equipment

HardwarePremix TanksReactorsFinishing TanksStorage TanksRelated UtilitiesAutomation/Controls

IT SystemsERPBI SolutionWorkflow AutomationSharePoint PortalDCS

Copyright 2011 MESA North American Conference

Copyright 2011 MESA North American Conference

HallWay – Continuous Improvement• HallWay is foundational for Hallstar growth strategy• Institutionalizing strong processes, leveraging

through growth in global markets• Developing lean toolkit to support operational

excellence and continuous improvement initiatives• Key strategic initiative of HallWay was to evaluate

manufacturing systems and automation– Largely manual processes undergoing automation over the

last five years - paper laden, verbal instructions, etc.– Recent investments focused on updating capabilities

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Motivating Factors• Automation

– Improve overall operational efficiency and ROA

• Paperless– Implement controlled electronic systems with better data

accessibility

• Lean Six Sigma– Foster continuous improvement initiatives, increase effective

capacity, decrease manufacturing variability and overall cost

• Manufacturing Intelligence– Centralized, correlated and accessible information for

decision support

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Evaluating Options• Off-the-shelf Solutions

– Evaluated a wide variety of MES Systems (batch and discrete) and systems for process manufacturers

– Required significant customization, high cost and/or significant changes to operations to pursue

• Custom Software Development– Valid option to consider, get exactly what you want but

undesirable based on resources, cost and time

• Workflow Automation based system– Customized functionality implemented in a platform based

system, best of both worlds

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Selecting Workflow Automation• Functionality tailored to current operations, systems

and manufacturing assets – we get exactly the functionality we want

• Flexibility to change and improve the system over time, supporting continuous improvement initiatives– Manual operations can be automated as justified by data– System easily extended to add new functionality

• Cost effective solution when compared to alternatives• Favorable implementation timeline

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Functional Overview• Batch MES

– Complete control of operations from ERP production request down to plant floor assets, raw materials to finished product

• Batch Recipe Management– Comprehensive solution for batch recipe creation and

management with versioning and controls

• Batch Record Management– Extensive product and process genealogy information

generated as products are manufactured – Correlated with process data

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Functional Overview - continued• Asset Management

– State based management of all production assets providing detailed availability, utilization and downtime reporting

• Comprehensive Process Data Collection– All time series process data (temperatures, pressures, etc.)

captured and stored in process data historian– All context based event data (batches, orders, equipment

states, etc.) stored in same process data historian

• Automation of SOPs and other business processes– Business processes like sampling and lab analysis requests

implemented as workflows and managed in the system

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Benefits of Approach• Standardization

– How we manufacture product is very well defined, managing change is a controlled process

• Compliance– Execution is enforced by system, issues are immediately

visible, escalated and resolved

• Visibility– Enterprise wide visibility into plant operations through

SharePoint Portal

• Manufacturing Intelligence– Incredibly detailed production and execution data available

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Selected Case Studies

• Recipe Management• Batch Record Management• Lab Data Management

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Recipe Management – The Issues

• 120 products with paper based production formulation and recipes (50-100 step standard operating procedures)

• Countless unit operating procedures• Executing was essentially a manual process,

as was creating new product SOPs– Supervisor prints the SOP, guides the

manufacturing process manually, fills out the form

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Recipe Management - Solution

• Recipes are now implemented as workflows that execute unit operations (manual and automated) to drive production

• All production related data “attached” to the workflow electronically– Recipe execution, unit operations and related

standard operating procedure data (i.e. lab data)– Data is available for analysis in situ and ex post

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Recipe Management - Solution

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Recipe Management - Solution

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Recipe Management - Benefits

• Standardization– Process of reviewing and building recipes

provided the opportunity to standardize across recipes and ensure more consistent production

• Secure, Organized, Version Controlled– Recipes are managed in a secure, version

controlled system, changes to recipes follow a defined process

• Accessible to Engineers / Domain Experts

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Batch Record Management - Issues

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Batch Record Management - Issues

• Paper-based nature operations led to unmanageable production related information

• Data was essentially inaccessible for use without significant effort

• New solution required to support lean and continuous improvement initiatives

• Electronic (paperless) solution addresses desire for more robust regulatory related data

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Batch Record Management - Solution

• Batch genealogy (product and process) related data is generated as production processes execute by system

• Visibility into batch record is provided through SharePoint portal with open interface for other systems (i.e. BI, OData, SQL/Excel)

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Batch Record Management - Solution

• Screenshot of batch record page

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Batch Record Management - Benefits

• Enterprise wide, clear visibility into current state of manufacturing– Plant manager can check status from home via

SharePoint Portal– Aids in passdown between shift changes

• From historical perspective, simple to get access to any data we want with little effort

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Lab Data Management - Issues

• Sampling and lab work is critical to execution of production and management of materials

• Like other SOPs, sampling and lab work was managed by manual, paper based processes

• Strong desire to optimize process to expedite batches through the manufacturing process– Define the work to be done– Prioritize important work (execution related)– Manage execution and information electronically

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Lab Data Management - Solution

• Sampling and lab work operating procedures were implemented as workflows

• Operators and technicians are tasked electronically by role to perform work

• Critical information is captured electronically, validated by system and used in execution

• Execution and data from workflows related to a batch are associated with the batch record

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Lab Data Management - Solution

• Screenshot of lab data action plan

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Lab Data Management - Solution

• Screenshot of lab user action from SharePoint

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Lab Data Management - Solution

• Screenshot of batch record

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Lab Data Management - Benefits

• Lab data being controlled electronically makes it considerably more accessible

• Previously, we only retained final lab results, now we have time series profiles of results

• Operationally, this is a big change for people, how they do their job

• Now processes have metrics associated with them, we can begin to better orchestrate

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Conclusion• Manufacturing is a core competency for HallStar,

workflow automation supports: – Continuous improvement and lean initiatives– Enforces standard work – Helping deliver quality products with less variability– Provides unprecedented level of Manufacturing Intelligence

• HallStar has a strong roadmap of lean and continuous improvement projects underway to improve manufacturing efficiencies based on workflow automation

Copyright 2011 MESA North American Conference

Workflow Automation as an alternative to Traditional MES

Jay [email protected]

Chuck [email protected]

Thank you for attending this session!