Automated Control Concepts, Inc. | 3535 Route 66, Neptune, NJ 07753 | p. 732-922-6611 | f. 732-922-9611 | e. info@automated-control.com

"Front Door to Back Door"

Overview

ACC’s Front Door-To-Back Door initiative applies a consistent methodology for using technology to track manufacturing resources from receipt of raw materials, to equipment usage, to personnel training and to completion of manufactured products. ACC’s approach begins with the design and study of the work flow, identifying interactions between business groups and functions, the information that is exchanged, and the format and triggers for data exchange. In similar fashion to a P&ID diagram, which provides data relevant to process equipment and instrumentation; a workflow analysis can be presented in a series of diagrams which describe informational flows, functional boundaries, security, timing and technical requirements for operations, engineering and information systems. Opportunities can be identified, design approaches can be discussed and detailed solutions and technology choices can be proposed. This methodology based on the emerging S95 standard, facilitates successful technical implementation and helps drive organizational "buy-in".

Application Types

Key areas where this approach is being applied by ACC are:

  • Equipment Status and Tracking
  • Material Tracking, Genealogy
  • Quality System Integration, CAPA, In Line / Lab SPC
  • Inventory Optimization, RFID

Project Examples

Firmenich – WORKFLOW INTEGRATION

  • Provide MES system to integrate to ERP (master materials and schedule release).
  • Disseminate production orders to work cells based on personnel, equipment capability and material types.
  • Collect data from various production work cells and reassemble as a response to ERP.
  • Integration to ERP for material inventory management, lot expiry checks, final product certificate of quality.
  • Material identification using bar coding and final product label / lot generation.
  • Winner of the Software Strategies Enterprise to Control Systems Integration Award, 1999.

Biotech Company – INTEGRATED BATCH REPORTING

  • ACC developed the strategy, and recommended and implemented tools for a configurable and flexible batch reporting application.
  • Project requirements driven by reporting and information needs
  • Data collection and reporting from many disparate data sources including a variety of OEM skids. ACC developed strategy, recommended and implemented tools to use for integrated reporting.

Pharmaceutical Formulation and Filling – MANUFACTURING PERFORMANCE ANALYSIS & BATCH REPORTING

  • ACC provided a Delta V system for a formulation and vial filling operation as part of a Part 11 remediation project.
  • Data collection to support analysis of manufacturing performance is enabled to both OSI PI and Delta V Batch Historians.
  • Reporting system software, “Infobatch” integrates different data sources into a set of manufacturing reports.

Worldwide Pharma Manufacturer – S95 INTEGRATION

  • Werum selected as MES standard and implemented successfully at one plant.
  • Use ISA-S95 to identify competent capabilities of existing MES and opportunities for more complete integration to existing and future automation.
  • ACC defines interfaces to MES system and standard modules for automation, integration to MES and recipe management.
  • World wide rollout of systems is planned.