Designing for High Performance Reliability during Project Phase

Emerson's Arturo Medina

Manufacturing capital projects have followed a similar path for many decades. The project team designs, executes and commissions the project, provides training for the operations staff, and hands it over to them to run. What is often lacking in this approach is the opportunity to design work practices at the design phase to improve overall reliability over the life of the manufacturing process.

In a Plant Services article, Roots in reliability, Emerson’s Arturo Medina describes ways to incorporate reliability tools and work practices during the project design phase to build a strong foundation for ongoing reliable operations.

Plant Services: Roots in ReliabilityArturo highlights the benefits of project teams and reliability champions collaborating during the project:

Project teams win by delivering faster, less-expensive, and more-successful implementations, while operations and reliability teams reap the benefits of having their own systems online and ready to go as soon as a new project is completed. Operations and reliability leaders who communicate and implement solutions beneficial to project implementation success and to long-term reliability can become project influencers, driving future decisions that incorporate operational certainty into project certainty.

He lists three key strategies to this approach: Continue Reading

Technology Advancements for Project and Operational Performance Improvements

At the recent ARC Industry Forum, Emerson’s Dave Imming and Claudio Fayad sat down with ARC Advisory Group’s Craig Resnick to discuss ways that technology is helping manufacturers improve both project and ongoing operational performance. Specifically, the conversation centered around the announcement of DeltaV version 14 at the conference.

I saw this tweet from @arc_advisory announcing the availability of the video interview:

In this 7-minute video, DeltaV New Features, IIoT & Performance Services: Dave Imming & Claudio Fayad of Emerson Automation, Dave explains the strategies around Operational Certainty and Project Certainty were the drivers for the technology advancements. Continue Reading

Digital Transformation for Safe Operations

One of the big topics last week at CERAWeek 2018 was the role technology can play to improve business performance—especially in areas such as safety, reliability and efficiency. These advancing technologies coupled with improved work practices can deliver a digital transformation to companies that undertake this journey.

At this week’s Safety Case Symposium 2018 Singapore conference, Emerson’s Jonas Berge is presenting, Digital Transformation Helping Your Safety Case. Here is the abstract:

Emerson's Jonas Berge

Singapore has embarked on implementation of Safety Case regime. Such regime has been implemented in the European Union and Australia. The regime requires MHIs [Workplace Safety and Health (Major Hazard Installations)] to demonstrate to regulators how risks from Safety Critical Events (SCEs) are being reduced to As Low As Reasonably Practicable (ALARP) and thereby ensuring safe operations in a sustainable manner.

A safety case is a written presentation of the hazards and risks that may lead to a major accident at an MHI and the technical, management and operational measures in place to control those hazards and risks. A safety case is commonly presented using, and communicated through a structured set of documentation that focuses on preventing major accidents at the installations, and limiting their consequences to people and the vicinity.

Continue Reading

Data Integrity for Pharmaceutical and Biotech Manufacturers

Update: This post has been updated with a link to the most recent Medicines & Healthcare products Regulatory Agency (MHRA) ‘GXP’ Data Integrity Guidance and Definitions – March 2018 document.

For pharmaceutical, biotech and other manufacturers in highly-regulated industries, the production data is as important as the product itself for release to sale. Data integrity of this production data is paramount.

Emerson's Michalle Adkins

I connected with Emerson’s Michalle Adkins about what manufacturers are doing to assure this data is accurate and timely. She shared with me some key regulatory standards and best practices.

Michalle noted that in recent years, the regulatory agencies for the Life Sciences industry, including the U.S. Food and Drug Administration (FDA), have increasingly observed Current Good Manufacturing Practices (cGMPs) data integrity issues during cGMP inspections.

Data integrity is defined as the completeness, consistency and accuracy of the data produced during the manufacturing process. The data must be attributable, legible, contemporaneous, original (or true copy), and accurate—ALCOA for short. It must also be enduring, complete, consistent and retrievable.

Global Pharmaceutical and Biotech Manufacturing Data Integrity StandardsCurrent regulatory guidance includes:

Michalle highlighted some of the key components of these global data integrity guidance documents. With respect to validation plans, procedures and processes, they should be documented including the evaluation of a system for criticality, applicability of electronic records and signatures, and system validation approach that includes the documentation and testing requirements. Continue Reading

Technology Advances in the Energy Sector

Emerson's Peter ZornioIn an Forbes article, Emerson CTO Says ‘Energy Industry 4.0’ Opens A Plethora Of Business Opportunities, Peter Zornio shares examples of the rapid innovations occurring in the energy sector. Peter noted the changing relationship with oil & gas operators:

“Emerson is cognizant of new demands for optimization from oil and gas customers, and my division is changing from being the proverbial ‘automation guy’ to a solutions partner in pretty much every area of the value chain except for drilling and completion.”

Software has advanced from its role in control systems. Peter explained that that the instrumentation and control system:

“…are now backed up by our prescriptive software, which in simple terms is a software that not only detects if there is something wrong or spots workflow issues, but can also help clients address that in the most cost efficient and fastest way possible.”

And these software advancements are being coupled with expertise: Continue Reading