AP08 - Eli Lilly Extends Visibility, Improves Life Cycle Management

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Eli Lilly Extends Visibility, Improves Life Cycle Management

Mirih Shah

Principal Controls Engineer

Eli Lilly and Company

BB50 Process Network Upgrade

About Lilly Corp & Branchburg

Eli Lilly Corporate:

• Based in Indianapolis, Ind.

– Fortune 500 Company

– In business 135+ years (Founded by Colonel Eli Lilly: May, 1876)

– Three core values: Integrity, Excellence, Respect for People

– One of top 10 biopharmaceutical companies

– 38,000+ Employees

– Operations in more than 40+ Countries

Branchburg, NJ:

• Formerly ImClone Systems

• Primary Manufacturing Location for monoclonal antibodies

6/2/2015 Company Confidential ©2015 Eli Lilly and Company 3

Lilly - Branchburg

Lilly-Branchburg, New Jersey

ImClone Branchburg Overview

Building 50 Operations

• Overview of manufacturing operations and

terminology

– Two manufacturing suites with space for a third

– Primary focus on Biopharma products

– State-of-Art biopharmaceutical manufacturing facility

• Commercial Products

– ERBITUX®

– Cyramza™

• Multiple Clinical Development Products

– 8MW solar field supplies over 50% of BB50’s needs


About Mihir

• 18+ years of experience in management, design & implementation of diverse automation control applications.

• Worked with MNCs in Pharmaceutical, Water, Chemical, Tire, Printing Press, Cement, Paper, Iron sheet galvanizing, and Textile Industry.

• Experience with Rockwell Automation®, Modicon & Siemen’s automation products

• Worked as Rockwell Automation® GTS engineer in India

• 10 years with Eli Lilly & Company

• Bachelor degree from India; MS in Project Management from Stevens; Six Sigma Green Belt certified


Process Control System

Migration Project Objective

• Needed to upgrade to contemporary (x64) Operating

Systems

• Justified Project

– Improve Life-Cycle Management

• Mitigate Risks within the Production Environment

• Fault-Tolerance/Recovery

• Improved Change Management (support rolling upgrades)

– Provide Visualization outside the suite

– Robust data collection


Project Approach

• Approach – 3 phases driven by ops schedule, engineering effort

• Architecture – FactoryTalk® Application Definition & Software Component Placement

• Multiple Applications

• Historian

– Virtualization (who would implement) • VMware: FactoryTalk® View SE, FactoryTalk® Alarms and Events, FactoryTalk®

Directory, RSLinx® Enterprise, FactoryTalk® Transaction Manager & FactoryTalk® Historian Site Edition Server & Remote HMI Clients

• Thin Manager: Plant floor Clients

– HMI Clients • Thin Manager (Bricks)

• Computers running VMware Client

– Development & Testing • Deployment of a Simulation environment including Network Infrastructure, Servers,

HMIs and PLCs


Project Approach

• Architecture (Continued)

– Expanded Visualization • Scenarios: Remote, Mobile, Support

– Alarming • HMI or FactoryTalk Alarms and Events

– Win911

– Network hardware • Enterprise Multi-Layer Switches

• Firewall

• Stakeholders – Core teams: AEG, IT, Process Engineering, Manufacturing,

Validation, QA

– Team members: ~12 (100% time) + ~10 (20-40% time)

– Roles defines based on area of expertise – Developer, IT, process SME, Validation, Quality Control,


Process Control System

Prior to Migration

• PCS based on ControlLogix® & RSView®32


PCS Network Architecture


Process Network Communication Flow

PCN Level-2

DMZ Level-3

Lilly Network Level-4

FTD for Hist & AC

Server: MS Reporting Services, Application for event data entry

Server: FTTM- MSSQL Database:

(Events, Alarms, CIP & Batch reports),

Reporting services, Automatic print out

Corporate Users

Area PLCs Skids PLCs

BRICK - FTVSE Area CLIENTS

Server: FT Historian SE-

PI Database

Thin Manager Secondary

Thin Manager Primary

VDIs for Areas View Only SE

Clients

VDIs for Skids View Only

SE Clients

BRICK – FTVSE Skid Client

VMWare Gateway for SE Clients and Station

- Skid flow path - Area flow path

- Historian flow path

RDS Servers for Area SE Clients

RDS Servers for Skid SE Clients

Corporate Users: SE View Only Clients – Laptop/ iPad

Skid – FTVSE + RSLinx Ent.

FTD for each Suite Skids

FTD for each Suite

Area: FTVSE svr Primary

Area: FTVSE svr Secondary

Server: MSTS – Process

Book, Excel

RSLinx Ent.-1, ICU-1, Primary

RSLinx Ent.-2, ICU-2, Secondary

PLCs Level-1

RSLinx Ent.-1, ICU-1, Primary

RSLinx Ent.-2, ICU-2, Secondary

Project Benefits (Results)

• Improved reliability due to Redundant Server/Client HMI

applications

• Reduced Time to recover Operator workstation

• Management remote access for status & troubleshooting

information

• Engineer & IT remote access for troubleshooting

• Reduced time to calibrate instrumentation


Visualization Access Enhancements

• Plant Floor

– ACP Thin Manager • RDS/Bricks for HMI clients

• Fault tolerance Clients

• Shadowing for troubleshooting

• Minimize hardware replacement time

• Corporate Users

– VMware View • View only client applications for live process status &

troubleshooting

• Same rights for users on process & corporate n/w


Data Collection Enhancements

• Transactional Data Collection – FactoryTalk Transaction Manager (~5K tags)

• Alarms & Event

• CIP & Batch

• Manual data entry

• Continuous Data Collection – FactoryTalk Historian ME (~800 tags)

• Bioreactors, CIP Skids, Area Applications

– FactoryTalk Historian SE (~2-3K tags) • Data through Redundant RSLinx® Enterprise & ICUs

• Site Repository Feed by Historian ME

• Plant floor & corporate users’ secure access


Challenges

• Defining scope for IT involvement

• Determining best tools for HMI software delivery

• FactoryTalk Application configuration (Data Servers)

• Alarming Configuration

• Project schedule shortened


Future / Next-Steps

• Suite 1 upgrade (Phase-2)

• FactoryTalk Historian SE (PI) Batch implementation

• Reports in FactoryTalk VantagePoint


Questions?


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AP08 - Eli Lilly Extends Visibility, Improves Life Cycle Management

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Transcript of AP08 - Eli Lilly Extends Visibility, Improves Life Cycle Management