Improving Raw Material Management Productivity

Emerson's Lynn Richard

For manufacturers in highly-regulated industries, such as pharmaceutical and biopharmaceutical manufacturing, it is critical to keep track of raw materials as part of the production records. To minimize or avoid waste, it’s also important to use the first-to-expire raw materials from inventory.

I caught up with Emerson’s Lynn Richard about his experiences to help a manufacturer solve this challenge and increase overall productivity.

In addition to the first-to-expire allocation rule, some other ones required include:

  • Using full containers from warehouse, as needed, to minimize operator weighing and loading
  • Allocating raw materials that have already received Quality Control (QC) team’s accepted status
  • Using open containers in the dispensary when less than a full container is needed
  • Sending a full container to the dispensary for partial use only if all that material in the dispensary has been used
  • Using raw materials in the customer sample laboratory exclusively for customer samples
  • Making potency adjustments before allocation

To address these challenges and requirements, Lynn and the project team developed an allocation component in the Syncade manufacturing execution system. A mixture of lot and container allocation with lot properties including QC status and warehouse location was designed. The container properties included the location in dispensary and location in customer sample laboratory.

Key logic steps performed in this allocation component include: Continue Reading

5 Questions for Digital Valve Controller and Safety Expert Riyaz Ali

Let’s continue our 5 Questions for an Emerson Expert podcast series with our guest, Riyaz Ali. You may recall Riyaz from numerous posts about digital valve controllers and final control elements in safety instrumented system applications. He has almost 40 years’ experience in process control instrumentation and holds numerous patents related to use of digital valve controllers for process industries.

Please leave me a comment or send me a LinkedIn message if there is an Emerson expert you’d like me to interview—and questions you’d like me to ask them—for a future podcast.


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The Value of Process Monitoring

Emerson's John Dolenc

Author: John Dolenc

What should you expect from a modern control system that you do not get from the older system now running your process? A major improvement in modern control systems is the ability to monitor the performance of the control loop. This includes how well the loop is managing to remain within an expected range of the set point.

HART instrumentation and positioners on the control valve along with asset management software can monitor field device performance and provide diagnostic information. Together this leads to early detection and notification of poor performing control loops causing process variability.

Properly planned control strategies should drive process equipment and unit operations to perform at optimum conditions. Knowledge that the process equipment and unit operations are performing as expected is not readily available using just the process measurements used to provide process control.

Instead, additional process information such as temperatures and flows on energy and utility streams are necessary to monitor process equipment performance. Think of the value of on-line real-time material and heat balance information for monitoring and troubleshooting unit operation performance. Continue Reading

Enabling Connected Services for Proactive Operations

As the Internet of Things and the Industrial Internet of Things technologies continue to advance, opportunities to run plants more safely, reliably and efficiently advance as well.

Emerson's Mike Boudreaux

At the Dell EMC World conference next week in Las Vegas, Emerson’s Mike Boudreaux will participate in two panel sessions. The first session on May 9 will be Keys to Successful Enterprise Internet of Things Initiatives moderated by Dell’s Kevin Terwilliger. The focus will be to help attendees:

…learn from real customers who have successfully deployed enterprise IoT initiatives and achieved ROI! How do you develop a business case to get the project funded, what is the right architecture for your use case, and how do you make sure you are appropriately investing in securing the data? We will answer these questions and many other to provide a check list for IoT success.

The second session, also on May 9, is How The Internet Of Things Is Changing The Way We Work. The focus is on solutions that: Continue Reading

Streamlining Oil & Gas Well Test Operations

The separation of oil, gas, produced water and sediments from producing oil & gas wells take place in production separators. Traditionally test separators were also installed to individually test the wells to determine their composition of these components. Technology advancements have opened up the opportunity to perform this multiphase measurement without the need for the test separator.

Emerson's Dew Divakaran

In this short, 2-minute video, Optimizing Well Testing Operations, Emerson’s Dew Divakaran describes how oil & gas producers can simplify these well testing operations through flow measurement and management technologies.

This approach combines a Bettis Multiport Flow Selector (MPFS) & Multiport Actuator (MPA) with a Roxar multiphase meter. The MPFS allows:

…the selecting and diverting of well fluids from an individual well to a single test outlet, flow loop or sampling device. Connecting up to seven flow lines, the Multiport Flow Selector allows the combined fluids to flow through a separate group outlet, while simultaneously isolating any single well for testing.

The MPFS reduces installation, operating and maintenance costs by reducing the number of isolation valves in production/test manifolds to provide more compact piping designs than either conventional two-way or three-way valve manifolds. Continue Reading