Identify and Resolve Cell Therapy Batch Manufacturing Exceptions

We conclude our series on improving cell therapy manufacturing with a closer look at the review by exception process.

In the manufacturing process of cell therapeutics, product cycle times are extremely short and any exceptions occurring during the production process must be found and addressed quickly.

Emerson's Bob Schiros

Emerson’s Bob Schiros notes that manufacturing execution systems, such as the Syncade MES, must include this exception reporting capability to address each of the thousands of batches manufactured each year. Getting batches out of the door faster – while ensuring quality – is especially important in the area of cell therapy manufacturing. Any delay can be catastrophic.

The review by exception functionality in the Syncade MES provides integrated exception reports to expedite the quality review processes, helping to quickly identify, review, and resolve issues during the batch production process.

By consolidating and logically presenting this data to the operators, it enables them to identify and resolve deviations that can impact product quality. Continue Reading

Stepwise Tank Gauging Modernization

Instrumentation for manufacturing continues to improve as the electronics grow ever more powerful. Modernizing instrumentation such as tank gauging level sensors on bulk liquids storage tanks has been made easier through emulation technology.

This quick, 1-minute YouTube video, Tank Gauging Emulation: Unlock the Potential in Your System, shows how older, less reliable level measurement devices can be upgraded, one-by-one, with the new instruments emulating the communications of the old instruments. Continue Reading

Podcast with Shutdowns, Turnarounds and Outages Services Leader John Sanders

Emerson’s John Sanders joins our continuing series of podcasts to share his insights on the process of effectively planning and executing plant shutdowns, turnarounds and outages. He also shares a surprising passion about chasing tornadoes, so make sure to listen in!

We hope you enjoy this podcast and please send me a note about other Emerson experts you’d like to hear from.

Emerson's John Sanders


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Strategies to Reduce Unplanned Downtime and Improve Operations

At the 2018 ARC Industry Forum, ARC Advisory Groups’ Craig Resnick led a panel session, Strategies to Reduce Downtime and Increase Plant KPIs. The description for this session was:

This session will discuss manufacturers’ biggest nemesis – unscheduled downtime – and strategies on how to reduce or eliminate it, subsequently increasing a plant’s key performance indicators (KPIs). Case studies will offer need-to-know guidance on “must haves” for OT leaders looking to maximize the ROI of their automation systems by eliminating any unscheduled downtime. Presentations will focus on learning to assess availability readiness of automation systems, as well as best practices to engage with IT decision makers. Learn how IT and OT convergence can align to deploy the best solution, one that fits into existing systems, supports standards including OPC, and delivers ROI, while laying the foundation to support modern technologies, such as virtualization and IIoT.

The first case study presented was a batch control application for a chemical production process. Ingredient additions were manually controlled and the control system manage blending, mixing and movements through the production process. The control system hardware managing the process had become obsolete. The human machine interface (HMI) was cluttered and did not effectively use colors as best practices recommended today. Continue Reading

Case Studies on Applying Analytics and Artificial Intelligence

ARC Advisory Group’s Janice Abel led a session, Digitizing Intelligence: From Analytics to Bots, at the 2018 ARC Industry Forum. The description for this session was:

Smart, connected real-time data that is synchronized throughout the plant and global enterprise is the future for process automation, the digital transformation, and smart manufacturing. Whether working with advanced analytics, machine learning, robotics, or chatbots, having connected industrial time stamped process data enables companies to make better data based decisions that can optimize production. Manufacturers need to integrate, manage, and obtain intelligence from large volumes of disparate data from sensors, machines, cameras, energy, financial, weather, and other data sources, to make more intelligent decisions faster.

The first case study presented was by an onshore oil & gas producer who is applying advanced analytics to maximize oil and gas production by detecting abnormal operating conditions in gas lift compression. The company uses a SCADA system to manage 29000 devices logging 52,000,000 records a day. Continue Reading