Maintenance and calibrations

© Bioproduction Group | www.bio-g.com 1/23/2014

Optimizing Maintenance and Calibrations

using Real-Time Scheduling

Jan 23, 2014

Rick Johnston, Ph.D. - Principal and Founder

Gary Wright - Senior Account Director, [email protected]

mailto:[email protected]



© Bioproduction Group | www.bio-g.com

Bioproduction Group

Founded in 2007 with an exclusive focus on

Biomanufacturing Operations

Primary goal of improving Quality,

Productivity, Flexibility and Operations in

Biomanufacturing

World Class “real time” data collection,

modeling, and simulation software

Technology Assisted

Knowledge Generation Tool

Specifically designed for the unique

needs of Analysts

Improving Quality, Productivity, Flexibility

and Operations at the World’s Largest

Biomanufacturers


Bioproduction Group is now used by more than

20% of the world’s biomanufacturing capacity*.

0

5

10

15

20

25

2007 2008 2009 2010 2011 2012 2013

% o

f w

orl

dw

ide c

ap

acit

y*

Year

1/23/2014 2 * As measured by total installed production bioreactor volume.


A collection of quotes*

1/23/2014 3 * Collected from 45 Bio-G phone interviews with biopharmaceutical

professionals from 16 companies, November 2012. Redacted for privacy.

Maintenance: “We got the OK, and turned

the power off. Turns out that also turned

off power to the skid in another part of the

facility, that was running a batch. Million

dollar mistake.”

Manufacturing: “Maintenance is always

trying to find out when equipment is

free… but to be honest we often don’t

know exactly ourselves.”

Manufacturing: “Calibrations? Mark does

that. It takes him about a week to find

places in the schedule where events will

fit. And every time we change our

schedule, he re-does his too. Patient

man.”

Maintenance: “I couldn’t count the number

of times I’ve gowned up, then found out

manufacturing will be using [the

equipment] till tomorrow. What a waste of

my day.” Manufacturing: “We tell our bosses we

schedule in SAP, but really? We use Excel

for detailed shop-floor scheduling.”


Maintenance vs. Manufacturing

1/23/2014 4


Scheduling Calibrations and Maintenance

is difficult

1/23/2014 5

Manufacturing

Maintenance / Calibrations

High Visibility

“Value Added”

Production Group

Low Visibility

“Necessary Evil”

Support Group


Significant delays are introduced by

these events*

1/23/2014 6

Manufacturing

Calibrations

Maintenance Downtime

Overall fraction of time

scheduled for events * Bio-G internal data, sourced from representative

biopharmaceutical manufacturers. Exact numbers redacted.

Manufacturing

Calibrations

Maintenance

Downtime Delays

Observed time

required for events


What causes these delays in

maintenance / calibrations?

Cause

"Equipmentunavailable"

"Manufacturing still inprocess"

"Maintenance tooklonger than expected"

"Co-ordination issues"

"Trained personnelnot present"

"Affects other part offacility"

1/23/2014 7

More than half of the reasons reported for delays were

due to poor scheduling or wrong information

Other


Fundamental problem: two systems are

competing for one resource

CMMS Planning

Equipment

1/23/2014 8

Computerized Maintenance

Management Systems (CMMS)

Equipment Manufacturing Planning

Manufacturing Systems

CMMS systems and production systems can’t “see”

each other’s schedules


For example: SAP*

1/23/2014 9

Plant Maintenance

Equipment Equipment Advanced Planning /

Optimization

* Bio-G is an SAP Certified Partner. Bio-G software is validated for use with SAP

Systems.

It is possible to schedule maintenance on a skid at the

same time that skid is being used for a process order

“Start calibration on

Chrom Col 1 at

2/1/2014 9:00am”

“Start downstream

Pro-A Cycling on

2/1/2014 12:00am” ???


Need a scheduling “arbiter” that

prioritizes the finite resources

1/23/2014 10

Plant Maintenance

Equipment Equipment Advanced Planning /

Optimization

“Start calibration on

Chrom Col 1 at

2/1/2014 9:00am” “Start downstream

Pro-A Cycling on

2/1/2014 12:00am”

Finite Scheduler

“Start Pro-A on 2/1/2014,

then Calibration on

2/5/2014”


Two Case Studies

1. “Simple Use” case study

– Take a plan (planned and production orders) from SAP and

schedule unit operations

– Take a schedule from a CMMS system and plan calibrations /

maintenance

– Publish that schedule out so it is visible

2. “Advanced Use” case study

– Use SAP for high level planning, but “blow out” a plan into

detailed production steps with work allocation

– Incorporate CMMS data (calibrations / maintenance)

– Allow users to publish and provide feedback on a schedule as it

is executed.

1/23/2014 11


Case Study 1

• SAP APO used to generate initial planned and production orders with

proposed (earliest) start times

• A CMMS system used to generate equipment maintenance /

calibrations events

• Bio-G’s Real-Time Modeling System used as an ‘arbiter’ to schedule

the two

• Outputs are published to Microsoft Outlook, a video planning board,

back to SAP, and to Excel

1/23/2014 12

CMMS Planning

SAP

* Bio-G is an SAP Certified Partner. Bio-G software is validated for use

with SAP Systems.

Bio-G Real-Time

Modeling System

Excel (duplicate

current output)

Outlook

(calendar)

TV on shop floor

Demonstration


Case Study: Takeaways

• Allows everyone to see an integrated view of the

manufacturing floor

– Different views for different groups (management, maintenance,

upstream, downstream)

– Incorporates both maintenance / calibrations and production plans while

optimally scheduling finite resources

• System is designed to be implemented in existing

enterprise architecture

– Supports most CMMS systems, SAP, DeltaV / Syncade, Rockwell

– No databases, “system administrators” or extensive training involved

– Less than one month setup and deployment (provided)

– Single person can run the system

– Can replicate current outputs, or provide “next generation” visualizations

like Outlook

• Supports “bring your own device” (BYOD)

– provided your corporate email is accessible from your email

1/23/2014 14


Traditional Scheduling Software only

solves half the problem

1/23/2014 15

Planner

Creates

Schedule

Published

Schedule

Run Facility

Based on

Schedule

“How can planners see and respond quickly

to events on the manufacturing floor?”


Bio-G’s software is designed to allow

real-time reaction to events

1/23/2014 16

Planner

Creates

Schedule

Published

Schedule

Run Facility

Based on

Schedule

Delays and

Rework

X Unexpected

Events


Create / Update

Publish

Execute Observe

Reconcile

This feedback loop is designed to be

familiar to the user and real-time.

1/23/2014 17

Smart

Phones

iPads

Laptops

Rockwell /

DeltaV / OSISoft

PI Historians

Rockwell /

DeltaV / OSISoft

PI Historians

DeltaV +

OSISoft PI

Historians


Case Study 2

• SAP and CMMS system as before

• Bio-G’s Real-Time Modeling System includes all of the detailed

manufacturing plan (down to detailed steps)

• Outputs are published to Microsoft Outlook, a video planning board,

back to SAP, and to Excel

• As the schedule executes, Outlook is used to communicate changes

back to the schedulers

1/23/2014 18

CMMS Planning

SAP

* Bio-G is an SAP Certified Partner. Bio-G software is validated for use

with SAP Systems.

Bio-G Real-Time

Modeling System

Excel (duplicate

current output)

Outlook

(calendar)

TV on shop floor

Two way integration

Demonstration


Case Study: Takeaways

• Enterprise Ready

– Can be used by multiple people across the enterprise at the same time

– What if scenarios, testing

– User access control and other advanced features

– No database administrator or IT support required

• Allows a simple method of reconciling changes to schedules

– Delays, late starts, notes and other issues communicated to the

scheduler in real-time

– Allows real-time adjustments to the schedule (more than once a day!)

• System can model all the complexity of biotech

– Media and buffer prep, transfer panels and valve arrays

– WFI systems and Labor / shift structures

– Variability in processing times

1/23/2014 20


Bio-G’s Technology Evaluation Program

• First three manufacturers who enroll in program are eligible

• Bio-G will setup the toolset

• Includes free 3 month evaluation

• 15 hours of consulting time with a Bio-G Engineer

– Set up of first model

– Training and Support to integrate with other data sources

• Free access to online training materials and the Bio-G wiki / help files

• Private WebEx demonstration for internal personnel

• Contact Gary Wright for more information

– [email protected]

– 510-725-9875

1/23/2014 21

RTMS

Crosswalk

Maintenance and calibrations

Data & Analytics

Transcript of Maintenance and calibrations