AP02: Amgen, Inc.: The No-Impact Migration – Upgrades in a Validated Environment

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Amgen, Inc.: The No-Impact Migration -Upgrades in a Validated Environment

Innovative Strategies in Migrating Legacy PLC5 Control Systems

Tom Lopez, Amgen

Richard Kleinfeld, M+W Automation

Agenda

• Company Background

• CEMS Implementation

• UCS Implementation

• Q & A

Amgen Today

World’s largest independent biotechnology company

~ 20,000 employees

> 75 countries

Reached millions of patients

For additional information about Amgen products, including important safety information, please visit amgen.com; Kyprolis® (carfilzomib) is developed and marketed (except in Japan) by Onyx Pharmaceuticals, an Amgen subsidiary; NEXAVAR® (sorafenib) is developed and marketed under collaboration and co‐promotion agreements between Bayer Healthcare and Onyx Pharmaceuticals

M+W Automation (MWA) Competence Network

AMERICAS EUROPE ASIA/PACIFIC

270 Employees

Headquarters:• Danbury, CT, USA

630 Employees

Headquarters:• Ludwigshafen, Germany

60 Employees

Headquarters:• Shanghai, China

• Austria• Belgium• Czech Republic• Germany• Ireland• Poland

• Russia• Switzerland• Slovakia• The Netherlands• Turkey

• Canada• Puerto Rico• USA

Chemicals Pharma & Biotech Food & Nutrition

Automotive Semiconductor Oil & Gas, Mining

Industries

Background:

• Critical Equipment Monitoring System (CEMS)

• Windows 2000 Upgrades initiated discussions for strategic review/replacement of obsolete hardware/software

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CEMS Implementation

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CEMS ImplementationBackground:

• Main Buildings in scope (I/O count):

• BA (120)• BB (45)• BC (80)• BD (240)• BE (720)• BF (180)• BG (200)• BH (690)

Total Buildings Upgraded: 11Total I/O: 2615

• Other Buildings/Sites:• BI (300)• SiteJ (45)

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CEMS Implementation

Business Case Detailed Design

Implementation/Testing

Commissioning

Traditional New Design BenefitsStand-Alone Installations Rockwell Client-Server-

architectureFully integrated design, Centralized software,Ease of maintenance/ change management

iFix HMI – Rockwell PLC integration

Rockwell HMI – Rockwell PLC

Amgen standard, Ease of integration, minimize training/ customization between vendors

iFix Data Collection/ Trending

PI Interfaces for each building

Amgen standard, more robust & reduce complexity/SPOF

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CEMS Implementation



Commissioning

Traditional New Design BenefitsiFix-based Alarm Generation

PLC-based Alarm Generation

More robust & reduce complexity

Custom HMI design Rockwell GEMS library Amgen standard, Rockwell COTS support

Win911 and HMI on common workstation

HMI on ServerWin911 on workstation

Dedicated workstation for Alarm Notification

Automation Hardware on business network (VLAN)

Automation Hardware on Manufacturing Network

Secure, dedicatednetwork for automation assets limits exposure to threats

Innovation and best practices helped drive our strategy

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CEMS Implementation

• GMAX contract (i.e. T&M Not Too Exceed)

• Competitively Bid

• Leverage a Bundled Approach

• Drive Savings



Commissioning

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CEMS Implementation



Commissioning

• Leverage common documents for multiple buildings• URS, FS, NDS, OIDS

• Generate site/building-specific documents• SDS, DT, IV/OV, RTM, VSR

Software Builds:

CEMS Implementation

CEMS ImplementationGEMS Library:

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CEMS Project Implementation



Commissioning

• Module Configuration Tool• Tag Rung Tool• Document Development Tool• Development Test in Parallel with live system• Development System on VM Environment• Mobile PLC for Parallel Communication

Module Configuration Tool:


Tag Rung Tool:


CEMS Project ImplementationDocument Development:

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CEMS Implementation



Commissioning

• Software tools developed, translate design docs to commissioning docs

• Minimal Validation Requirements• Minimal Downtime• I/O Wiring Conversion

I/O Wiring Conversion:

CEMS Implementation

• What is Virtualization?

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UCS Implementation

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• Benefits:• Less Physical Infrastructure to Maintain• High Application Availability• Stable System Modifications• Lifecycle costs

• Risks:• Network Issues• Software/Application Compatibility• VMWare Robustness• Novel technology

UCS Implementation

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UCS Implementation

Project Results

• CEMS downtime required for startup 4 hours.

• On time under budget for 8 consecutive startup scheduled 1 month apart

• Solution can perform JackPanel functions with no invasive action

• Automation solution is on a segregated Manufacturing Network

• Maintenance cost reduced

• 30% Cost Avoidance/Savings from Original Estimate

Questions?

Tom Lopez, Amgen

Richard Kleinfeld, M+W Automation


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AP02: Amgen, Inc.: The No-Impact Migration – Upgrades in a Validated Environment

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Transcript of AP02: Amgen, Inc.: The No-Impact Migration – Upgrades in a Validated Environment