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

"Paper to Process"

Overview

Paper to Process seeks to improve manufacturing efficiency and quality by integrating paper based records into automation and information technology systems that exist in today's plant. Paper to Process recognizes that companies do business in a legacy paper paradigm, where work instructions, data collection and operating procedures are bound to paper. These businesses, while operating in paper, use sophisticated technical equipment and assets every day to manufacture their key products. The goal of Paper to Process is to link paper records into the automation, removing time delays, double entries, quality issues and errors.

Application Types

ACC’s Paper-to-Process approach enables the following applications:

  • Integrated Manufacturing Work Instructions
  • Customer Drug Trial Data Entry
  • Personnel Training Records
  • Electronic Batch Records

Project Examples

Biotech Manufacturer – BIOPROCESS DATA COLLECTION & ANALYSIS

  • Bioprocess manufacturing environment.
  • Replaced existing manual data collection from Excel™ spreadsheets.
  • Resulting system is largely manual entry, with multiple route and approve, animation for data entry errors, out of process range errors and summary reports.
  • Time improvements realized for reviewing batch records by managers.
  • System is primarily manual entry, but includes automated data collection and legacy data import capabilities.
  • Success is demonstrated by the system being embraced by the users and plans to expand to two additional factories.

Leading Life Sciences Company – PAPERLESS TEST & TRAINING SYSTEM

  • Developed paperless test and training system.
  • Secure web-based delivery of operations testing.
  • Allow for development of new tests, manage core questions, random test question order and selection.
  • Allow for reporting on employee certification status, test horizon requirements.
  • Integration to company ERP, PeopleSoft.

Major Pharmaceutical Manufacturer - MES STRATEGY DEVELOPMENT

  • Worked with corporate MES team to develop strategy, technology test bed.
  • Team divides MES components into upper tier and lower tier levels, where lower tier technologies would be deployed and maintained by the plants. Pro-Pack data selected to provide upper tier capabilities.
  • Combined the use of the S88 and S95 models with comprehensive workflow analysis to develop functional requirements for lower tier MES.
  • Worked with key product vendor and customer on the development and testing of an electronic work instruction product for S88 batch engine.
  • Implemented four systems integrated with batch control, electronic work instructions and batch reporting at two manufacturing sites.
  • Implemented web based, plant wide manufacturing reporting.

Major Pharmaceutical Manufacturer – DOCUMENT TO BATCH INTEGRATION

  • Desire to integrate manual data entry to existing batch system.
  • Utilizing electronic work instruction product, integrated to existing batch system using BatchML (XML Instantiation of the ISA-S88 standard).
  • Resulting system allows batch record to be managed by the document management system.
  • Released batch record “instantiates” recipe components as required in the batch system, collects results and integrates to overall document.
  • Finalized batch record has both manual and automated data, ready for route and approve.