Presented by
© Copyright 2012 OSIsoft, LLC.
MES Integration with the OSIsoft PI System
Barry Higgins
© Copyright 2012 OSIsoft, LLC.
Agenda • Introduction
• Why MES in API
• Solution Architecture
• PI System / MES Integration
• Benefits and Next Steps
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© Copyright 2012 OSIsoft, LLC.
Introduction – About Janssen
§ 3 key business sectors: § Consumer § Medical Devices &
Diagnostics § Prescription Products
§ JSC API Supply Chain § Chemicals – 6 sites § Biologics – 5 sites
§ Worldwide Pharmaceutical sales of $6.1 billion in Q1 2012
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© Copyright 2012 OSIsoft, LLC.
Introduction – JSC API Supply Chain
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CHEMICALS Athens, GA Cork, Ireland Geel, Belgium* Schaffhausen,Switz Wilmington, DE Westbury, Tasmania
BIOLOGICS Cork, Ireland Leiden, Netherlands Malvern, PA Manati, PR
© Copyright 2012 OSIsoft, LLC.
Introduction – OSIsoft Products and Services
• Janssen & OSIsoft Enterprise Agreement • PI Server (High Availability) • PI Asset Framework • PI Interfaces
– PI OPC interface – PI UFL interface – PI Batch interface – PI RDBMS interface
• RtReports • PI WebParts • PI Manual Logger
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© Copyright 2012 OSIsoft, LLC.
PI System in Janssen API SC • PI System in place in Cork, Ireland (2
sites) and Geel, Belgium. • Deploying PI System as part of an
MES readiness projects to: – Leiden, Malvern, Manati, Springhouse,
Schaffhausen • Collecting all process data, alarms &
events and batch event data. • This provides a common data
presentation layer for MES, independent of control system platform.
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© Copyright 2012 OSIsoft, LLC.
Agenda • Introduction
• Why MES in API
• Solution Architecture
• PI System / MES Integration
• Benefits and Next Steps
7
© Copyright 2012 OSIsoft, LLC.
Why MES in API – Expected Benefits 1) Automate the manufacturing workflow
2) Streamline the release process
3) Replace existing bespoke legacy systems with a single standardised manufacturing system
4) Eliminate the ‘hidden-factory’ related to the current paper based process, e.g. effort to generate, maintain, correct, distribute batch records, logbooks, etc.
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© Copyright 2012 OSIsoft, LLC.
Agenda • Introduction
• Why MES in API
• Solution Architecture
• PI System / MES Integration
• Benefits and Next Steps
9
© Copyright 2012 OSIsoft, LLC. 10
Production order status Material consumptions Inventory update
Master material data Overall inventory
Material lot status Production orders
Sample IDs
Act
ual
val
ues
Process Control System(s)
ERP
PAS|X
Material Master Overall Inventory Overall Genealogy Master Batch Record Master Production Schedule Production Orders
Production Resource Management Detailed Master Batch Records Production Plan Execution Electronic Batch Recording Weigh & Dispense Review by Exception Material Management in Production
Training Management
Building Automation System(s)
DMS SOP’s / WI’s Drawings Instructions
IPC instruments
LIMS
J&J Users (LDAP / AD)
CAPA Set
val
ues
Tele
gram
s
Login verification
UserID & PW
Doc
ID
File
Manual Interface
Sync
hron
izat
ion
Proc
ess
data
Ala
rm &
Ev
ents
Manual Interface
Global
MES
Local
Proc
ess
data
, Bat
ch d
ata,
Ala
rm &
Ev
ents
OSIsoft PI System (Historian)
Scales &
Printers
System Architecture – System Overview
© Copyright 2012 OSIsoft, LLC.
System Architecture – The New Trinity • PAS|X Commands & setpoints to Process Control System • Process Data collected in the PI System • The PI System data referenced in the PAS|X EBR • PAS|X EBR batch execution data referenced in the PI System
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Process Control System(s)
PI System
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© Copyright 2012 OSIsoft, LLC.
System Architecture – PI Centric Architectural View
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PI Server Collective PI AF
Collective
API nodes
Manufacturing Data Sources
© Copyright 2012 OSIsoft, LLC.
Agenda • Introduction
• Why MES in API
• Solution Architecture
• PI System / MES Integration
• Benefits and Next Steps
13
© Copyright 2012 OSIsoft, LLC. 14
• A database of user configured “Process Object Models” called elements which represent the logical components in your process.
• Allows data from multiple PI Servers to be combined in one common view.
• Allows the user access to non PI System data sources, e.g. external databases.
• Allows process specialists to build process relative models without the need for extensive PI System knowledge.
PI Asset Framework – What is PI AF?
© Copyright 2012 OSIsoft, LLC. 15
• A database of user configured “Process Object Models” called elements which represent the logical components in your process.
• Allows data from multiple PI Servers to be combined in one common view.
• Allows the user access to non PI System data sources, e.g. external databases.
• Allows process specialists to build process relative models without the need for extensive PI System knowledge.
PI Asset Framework – What is PI AF?
© Copyright 2012 OSIsoft, LLC. 16
Super Class concept. • Class based templates – built in
conjunction with process and subject matter experts.
• Only process critical information grouped together in a logical model.
• Ensures that the entire organisation have a common taxonomy.
PAS|X \ PI AF • Using Unit based templates allows us to
build unit based MBR elements that can be applied on other sites.
PI Asset Framework – PI AF in Janssen
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Different Bio Reactors on various sites all classed under one common schema
PI Asset Framework – Similar Equipment all talking the same language
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Different Bio Reactors on various sites all classed under one common schema
PI Asset Framework – Similar Equipment all talking the same language
© Copyright 2012 OSIsoft, LLC.
PI Asset Framework – From PI AF to eBR
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PI AF Element Templates • Class based template.
• Unit Elements created from template.
Upload from PI AF • Class based PCS MBR elements
• Building blocks for MBR modellers
MBR Generation • Class based MBR
EBR Execution • Unit resolved at run-time.
• Data retrieved from PI AF Unit Element
© Copyright 2012 OSIsoft, LLC.
PI Asset Framework – Production Analysis using PAS|X to PI Batch • OSIsoft and Werum collaborated to develop the Werum PAS-X
Batch Interface which will become standard OSIsoft product. • This enables us to perform batch analysis at the EBR level from a
Basic Operation (BO) or Basic Function (BF) perspective.
• The capability to store basic function activities as batch events is similar to current DCS batch events.
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• Allows Janssen to track, compare and analyse MES batches using standard tools.
• From Order creation in SAP to finished product delivered.
PI Asset Framework – PAS|X to PI Batch \ PI Event Frames
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• Allows Janssen to track, compare and analyse MES batches using standard tools.
• From Order creation in SAP to finished product delivered.
PI Asset Framework – PAS|X to PI Batch \ PI Event Frames
Livepoint from Mirabo Systems
© Copyright 2012 OSIsoft, LLC.
PI Asset Framework – PAS|X to PI Batch \ PI Event Frames
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• Interface allows us to write to PI Event Frames.
• Allows for data from any PI AF data source to be put into an configurable timeframe context
© Copyright 2012 OSIsoft, LLC.
PI Asset Framework – PAS|X to PI Batch \ PI Event Frames • Interface allows us to
write to PI Event Frames.
• Allows for data from any PI AF data source to be put into an configurable timeframe context
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Livepoint from Mirabo Systems
© Copyright 2012 OSIsoft, LLC.
PI Batch or PI Event Frames • PI Batch and S88
constraints. • Cannot leverage
PI AF.
• Flexibility to build recipe templates.
• Third party client tools.
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© Copyright 2012 OSIsoft, LLC. 26
The PI System Effect • pH testing before:
Result in batch record, printout and copy are reviewed before batch release.
Batch Record instructs technician to take pH sample.
Technician takes sample and performs test and prints out result.
Technician copies result and attaches it to Batch Record and records result.
Technician manually checks pH meter logbooks.
© Copyright 2012 OSIsoft, LLC. 27
The PI System Effect • pH testing after:
EBR prompts Technician to. Take pH sample.
Technician scans pH meter for status
Technician performs pH test and result is sent to the PI System
PAS|X requests result from PI AF
Result is evaluated, during EBR execution.
© Copyright 2012 OSIsoft, LLC.
PI Asset Framework • One Screen,
multiple sources of live data.
• Visual Equipment status
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PI Asset Framework - Visual Equipment log
One location for multiple data sources: • MES data • SAP data • OSIsoft PI System data • QA information
© Copyright 2012 OSIsoft, LLC. 30
PI Asset Framework – Visual Equipment Status
© Copyright 2012 OSIsoft, LLC.
Agenda • Introduction
• Why MES in API
• Solution Architecture
• PI System / MES Integration
• Benefits and Next Steps
31
© Copyright 2012 OSIsoft, LLC.
Why MES in API – Expected Benefits 1) Automate the manufacturing workflow
2) Streamline the release process
3) Replace existing bespoke legacy systems with a single standardised manufacturing system
4) Eliminate the ‘hidden-factory’ related to the current paper based process, e.g. effort to generate, maintain, correct, distribute batch records, logbooks, etc.
32
© Copyright 2012 OSIsoft, LLC.
Benefits Realised Removal of 1002 paper
documents (to date) from Manufacturing
• Interface of Scales to the PI System and PAS-X eliminates manual entries
• Automated pH/Cond/Osmo/Filter integrity testing. Result retrieval directly from the instrument to the PI System
Greater Visibility on Status of Orders
• Process is tracked from Warehouse to Manufacturing to Warehouse
Exception Free Manufacturing
• Mistake proofing in area of GDP errors and partially completed ‘Paperwork’ eliminated
• No more searching for Docs / SOPs; automatically linked to Master Batch Record
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© Copyright 2012 OSIsoft, LLC.
Future Plans and Next Steps • Complete roll out of PAS|X to remainder of site.
• Display process relevant data from PAS|X on shop floor using standard PI System tools, PI ProcessBook, PI DataLink
• Begin analysis of data gathered by the PI System from PAS|X to discover the next ‘hidden-factory’
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4) Compliance – Eliminating Good Documentation Practice errors. – Enforced workflow.
5) Productivity
– Interface with plant systems eliminates manual data entry steps. – Process Data historian, LIMS, Balances etc. interfaced – Interface with LIMS eliminates manual steps. – System checks greatly reduce the number of operator verification steps (system acts as witness).
6) Continuous Improvement
– Real-time data in batch context facilitates process improvement efforts. – Real-time material transactions highlight scrap reduction opportunities.
Why MES in API – Expected Benefits cont. Barry – I think this slide is largely covered in the last side. Can we remove this one?
© Copyright 2012 OSIsoft, LLC. 38
4) Compliance – Eliminating Good Documentation Practice errors. – Enforced workflow.
5) Productivity
– Interface with plant systems eliminates manual data entry steps. – Process Data historian, LIMS, Balances etc. interfaced – Interface with LIMS eliminates manual steps. – System checks greatly reduce the number of operator verification steps (system acts as witness).
6) Continuous Improvement
– Real-time data in batch context facilitates process improvement efforts. – Real-time material transactions highlight scrap reduction opportunities.
Why MES in API – Expected Benefits cont. Barry – I think this slide is largely covered in the last side. Can we remove this one?
© Copyright 2012 OSIsoft, LLC. 39
PI AF - PAS|X • Class based templates –
built in conjunction with process and subject matter experts.
• Ensures that only process critical information from a number of data sources can be grouped together in a logical model.
© Copyright 2012 OSIsoft, LLC. 40
PAS|X to PI Batch • Allows us to track, compare and analyse MES
batches using standard tools
© Copyright 2012 OSIsoft, LLC.
System Architecture – PI System / PAS|X
41
© Copyright 2012 OSIsoft, LLC. 42
Different Bio Reactors on various sites all classed under one common schema
PI Asset Framework – Similar Equipment all talking the same language
© Copyright 2012 OSIsoft, LLC. 43
Where does the PI system fit in ?
Production Data
Collection
Production Execution
Management
Production Resource
Management
Production Dispatching
Production Tracking
Production performance
Detailed Production Scheduling
Production schedule
Product Definition
Management
Production level 1-2 functions
Production Performance
Analysis
Production capability
Product definition
Equipment and process specific production rules
Equipment and process specific data
Operational responses
Operational commands
MES
OSIsoft PI