D e c e m b e r 2 0 1 8 Issue 58

Single Version of Truth - Beyond Productivity

Simplifying Biopharmaceutical Production with Single-Use Systems

Modern Batch Systems Help Solve Today’s Market Challenges

Digital Transformation in the Pharmaceutical Industry

Inside

ASIA PACIFIC TODAY

Issue 63

Single Version of Truth - Beyond Productivity

m a in te x t

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Contents

Copyright© 2020 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner.

Joseph Sousa, PresidentAsia Pacific Region, Rockwell Automation

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EXECUTIVE MESSAGE

To s u b s c r ib e o r u n s u b s c r ib e , v is i t :https://map.rockwellautomation.com/subscribe

T r a c e a b i l i t y T a k e s P r e c e d e n c e

C o n su m e rs a re d e m a n d in g m o re c h o ic e s . R e g u la t io n s a re g e t t in g t ig h te r a n d o p e ra t io n s a re b e c o m in g m o re c o m p le x . A s to d a y ’s d y n am ic m a n u fa c tu r in g in d u s t r y c o n t in u e s to p re s e n t m u lt ip le c h a lle n g e s , c o m p a n ie s a re n o w m o re

th a n e v e r re q u ire d to e m b ra c e th e la te s t te c h n o lo g ie s to u n c o v e r n e w c o m p e t it iv e a d v a n ta g e s .

D ig it a l t r a n s fo rm a t io n h a s b e c o m e im p e ra t iv e fo r m a n u fa c t u re r s f a c in g s h if t in g c u s to m e r e x p e c t a t io n s , u n c e r t a in g lo b a l t ra d e a n d c o s t p re s s u re s , a n d w o rk fo rc e s h o r ta g e s . It c a n h e lp c o m p a n ie s e s ta b lis h c o n n e c te d o p e ra t io n s a s a w a y to re m a in c o m p e t it iv e a n d b e t te r s e r v e th e ir c u s to m e rs .

A s re g u la t io n s a n d c o m p lia n c e re q u ire m e n t s c o n t in u e t o t ig h t e n , a t r a c e a b ili t y i n f r a s t r u c t u r e i s n o l o n g e r o p t i o n a l b u t n o w e s s e n t i a l . W h e t h e r y o u a r e a p h a rm a c e u t ic a l, m e d ic a l d e v ic e o r c o n su m e r p a c k a g e d -g o o d s m a n u fa c tu re r, y o u a re n o w re q u ire d to t ra c k a n d t ra c e p ro d u c ts a c ro s s th e s u p p ly c h a in .

In fa c t , a n u m b e r o f c o u n t r ie s a ro u n d t h e w o r ld a re in t h e p ro c e s s o f ro llin g o u t s e r ia liz a t io n -b a s e d a n t i-c o u n te r fe it in g re g u la t io n s . A re c e n t s tu d y fo u n d th a t w h ile o n ly 2 3 p e rc e n t o f m a n u fa c t u r in g c o m p a n ie s h a d t h e p ro c e s s e s a n d s o f tw a re in p la c e to e n a b le e n d -to -e n d t ra c e a b ilit y , a ro u n d 6 0 p e rc e n t p la n n e d to h a v e th e s e in p la c e in th e n e x t y e a r.

T h is is s u e o f A u to m a t io n To d a y d e lv e s d e e p in to h o w a t ra c e a b ilit y in f ra s t ru c tu re c a n h e lp im p ro v e y o u r t im e to m a rk e t , m a n u fa c tu r in g p ro c e s s e s a n d c o m p lia n c e . I t fo c u s e s o n h o w t h e la t e s t t e c h n o lo g ie s c a n h e lp m a n u f a c t u re r s m a k e t h e i r p ro d u c t io n s y s te m s m o re fl e x ib le a n d e ffi c ie n t .

I t f e a t u r e s t o p i c s e s s e n t i a l t o e s t a b l i s h i n g a t r a c e a b i l i t y i n f r a s t r u c t u r e , i n c lu d in g : Single Version of Truth – Beyond Productivity; Simplifying Biopharmaceutical Production with Single-Use Systems a n d ; Modern Batch Solutions Help Solve Today’s Market Challenges. T h is is s u e a ls o in c lu d e s t h e la te s t p ro d u c t s a n d te c h n o lo g ie s , c u s to m e r c a s e s tu d ie s th a t d e m o n s t ra te h o w w e h e lp c u s to m e rs a d d re s s th e ir a p p lic a t io n c h a lle n g e s a n d re c e n t c o m p a n y n e w s a n d e v e n ts . I h o p e y o u e n jo y th is is s u e o f A u to m a t io n To d a y a n d th a t it h e lp s y o u id e n t ify n e w a n d in n o v a t iv e te c h n o lo g ie s fo r y o u r d ig ita l t ra n s fo rm a t io n jo u rn e y .

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News & EventsT h e la te s t n e w s a n d e v e n t s f ro m R o c kw e ll A u to m a t io n A s ia P a c ifi c

Cover Story – S in g le Ve rs io n o f T ru th - B e y o n d P ro d u c t iv it y

Case Studies

Technology WatchS im p lify in g B io p h a rm a c e u t ic a l P ro d u c t io n w ith S in g le -U s e S y s te m s

Application ProfileM o d e rn B a tc h S o lu t io n s H e lp S o lv e To d a y 's M a rk e t C h a lle n g e s

Product & Solution FocusIn t ro d u c in g th e la te s t a n d u p d a te d te c h n o lo g ie s a n d s o lu t io n s fo r sm a r te r o p e ra t io n s

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Automation Today Asia Pacific April 2020, Issue 63

This magazine is published 4 times a year byROCKWELL AUTOMATION Inc. for Asia Pacific

India5th floor, Tower B, Building No 10, DLF CybercityGurugram 122002Ruchi Mathurrmathur@rockwellautomation.com Singapore2 Corporation Road, #04-05/06, Corporation PlaceSingapore 618494Anne Chng achng@rockwellautomation.com

South Pacific 841 Mountain HighwayBayswater, Victoria 3153Sally Sau Lan Laislai2@rockwellautomation.com

We work with top biotech, pharma, and device

manufacturers to make their life sciences facility

of the future a reality. Together, we advance

industrial transformation with new technologies,

innovative solutions, and shorter timelines to

improve patient outcomes.

Allen-Bradley, ArmorBlock, Automation Today Asia Pacific, Compact 5000, CompactLogix, ControlLogix, FactoryTalk, GuardLogix, Guardmaster, Guardshield, Integrated Architecture, Kinetix, LISTEN. THINK. SOLVE., Micro800, PanelView, PartnerNetwork, PharmaSuite, PlantPAx, POINT I/O, PowerFlex, Rockwell Automation, Stratix, Rockwell Software, Studio 5000, ThinManager, VantagePoint, VersaView, are trademarks of Rockwell Automation, Inc.

EtherNet/IP is a trademark of ODVA, Inc.

Microsoft Azure is a trademark of Microsoft.

All other trademarks are the property of their respective owners.

We work with top biotech, pharma, and device

manufacturers to make their life sciences facility

of the future a reality. Together, we advance

industrial transformation with new technologies,

innovative solutions, and shorter timelines to

improve patient outcomes.

NEWS & EVENTS

4 ASIA PACIFIC

A n in t u i t iv e s h i f t t o w a r d s g r e a t e r a u t o m a t io n - A n th o n y W o n g , R e g io n a l D ire c to r

– S o u th P a c ifi c R e g io n , R o c k w e ll A u to m a t io n

A u to m a t io n a n d re m o te o p e ra t io n s a re o n th e m o v e . N o w h e re w a s th is m o re c le a r th a n a t o u r re c e n t R o c kw e ll A u to m a t io n O n T h e M o v e - a u n iq u e e v e n t w h e re fro m 3 -4 M a rc h w e s aw 1 1 9 c u s to m e rs a t te n d 1 5 b re a k o u t s e s s io n s

in A u c k la n d , N e w Z e a la n d , e n g a g in g w ith n e w t re n d s , n e w te c h n o lo g y a n d e a c h o th e r.

I t w a s t ru ly a h a n d s -o n e x p e r ie n c e w h e re c u s t o m e r s a p p ly t h e la te s t a u to m a t io n a n d re m o te o p e ra t io n s te c h n o lo g y to a b u s in e s s p ro b le m , w ith th e s u p p o r t o f a n e x p e r ie n c e d te c h n ic ia n , w o rk in g a lo n g w ith t h e ir t e am . I t w a s a c h a n c e to d e m y s t ify In d u s t r y 4 .0 a n d t h e re a lit y o f w h a t a u to m a t io n a n d IT /O T c o n v e rg e n c e c a n m e a n fo r b u s in e s s e s - m a k in g it re a l fo r c u s to m e rs . I n c r e a s e d d e m a n d f o r a u t o m a t i o n T h is is c r it ic a l a n d b e c o m in g m o re im p o r t a n t w ith e a c h p a s s in g d a y . B u s in e s s e s w a n t to g e t to m a rk e t q u ic k e r. T h e y w a n t to k n o w h o w t h e y c a n le v e ra g e d a t a b e t t e r t o im p ro v e p ro d u c t iv it y a n d s u s ta in a b ilit y .

T h e n t h e r e 's t h e c h a l l e n g e o f a c c e l e r a t i n g l e a r n i n g . M a n y k n o w le d g e a b le v e t e r a n s w ill r e t i re . A t t h e s a m e t im e , y o u n g e r g e n e r a t i o n s c h a n g e j o b s m o r e r e a d i l y a n d b u s i n e s s e s a r e s t ru g g lin g to f in d p e o p le w h o w a n t to liv e a n d w o rk in h a rs h o r re m o te c o n d it io n s . C o ro n a v iru s is e n c o u ra g in g s o m e c o m p a n ie s to e x p lo re in c re a s e d a u to m a t io n s o lu t io n s a n d re m o te o p e ra t io n s d u e to th e c h a lle n g e s p o s e d t o b u s in e s s o p e ra t io n s . A lo t o f c u s t o m e r s , p a r t n e r s a n d e n g in e e r s a re u n a b le t o g o o n to s it e r ig h t n o w . I e x p e c t t h is t o c h a n g e th e w a y w e th in k a b o u t h o w w e c a n ru n p la n ts e ff e c t iv e ly w ith o u t p e o p le o n s ite .

M a n y c h a l l e n g e s a r e n 't d i ff e r e n t – b u t t h e t e c h n o l o g y i s W h ile C O V ID -1 9 m a y b e t h e la t e s t a n d g re a t e s t t h re a t , m a n y o f th e c h a lle n g e s b u s in e s s e s fa c e to d a y a re n o d iff e re n t to 2 0 y e a rs a g o . B u s in e s s e s w a n t to k n o w h o w to g e t in fo rm a t io n to d e c is io n m a k e rs in a t im e ly w a y , p a r t ic u la r ly w h e n m a n y IT s y s te m s d o n o t in te r fa c e e a s ily w ith o n e a n o th e r.

It w a s h a rd to c o r re la te o r fi n d m a n u fa c tu r in g t re n d s . T h e re w a s to o m u c h d a ta th a t to o k to o m u c h t im e to re t r ie v e a n d w a s n o t re a l-t im e . W e b u ilt c u s to m , c o s t ly a n d c o m p lic a te d o n e -s id e d s o lu t io n s .

W ith th e a r r iv a l o f In d u s t r y 4 .0 , t h e te c h h a s a c c e le ra te d , a n d w e c a n d o th in g s d iff e re n t ly . D ig ita lis a t io n is th e n e x t q u a n tu m le a p in te rm s o f t r y in g to g e t m o re d o n e w ith y o u r s y s te m s .

T h e c o n v e rg e n c e o f IT a n d O T c a n h e lp u s m a k e s e n s e o f a s m u c h d a ta a s is a v a ila b le a n d p ro c e s s it in a t im e ly w a y . M a c h in e le a rn in g c a n a s s is t w ith a u to m a t io n a n d s p o t t in g t re n d s , a n d a u g m e n te d re a lit y (A R ) c a n s u p p o r t a c c e le ra te d le a rn in g , re m o te t ra in in g a n d

e n h a n c e d o p e ra to r e x p e r ie n c e . A R h a s p a s s t h r o u g h t h e h y p e p h a s e a n d i s n o w p a r t o f t h e m a in s t re am . It 's a llo w in g th e o v e r la y o f th e d ig ita l a n d th e p h y s ic a l w o r ld s . T h is in c lu d e s b o th b e in g a b le to v is u a lis e a n d m o v e a ro u n d a m a c h in e t h a t is n 't p h y s ic a lly t h e re a n d b e in g a b le t o o v e r la y a p h y s ic a l m a c h in e w it h a n A R v is u a lis a t io n , w h ic h c a n s u p p o r t t ra in in g a n d m a in te n a n c e . B e h in d th is s h if t lie s th e fa c t th a t s e n so rs h a v e c o m e d o w n in p r ic e , c o m p u t in g p o w e r h a s g o n e th ro u g h th e ro o f, la te n c y h a s re d u c e d , c lo u d c o m p u t in g h a s n o w b e c o m e p e r v a s iv e in o u r l iv e s a n d c y b e rs e c u r it y h a s b e c o m e to p o f m in d . W h e re a s in t h e p a s t w e s a w t h a t m a n y IT p ro je c t s t e n d e d n o t t o fa il b e c a u s e o f t e c h b u t b e c a u s e o f is s u e s w it h a d o p t io n a n d u n d e rs t a n d in g , u s a b ilit y a n d u s e r e x p e r ie n c e a re n o w b e c o m in g a p r im a r y o b je c t iv e o f m a n y s o lu t io n s - a n d t h a t w ill a llo w m o re s u c c e s s fu l p ro je c t s . A lo t o f th e te c h is b e c o m in g c o n fig u ra b le a n d o p e n . W h a t th is m e a n s is th a t b u s in e s s e s c a n n o w m a k e s e n s e o f a s m u c h d a ta th a t is a v a ila b le a n d p ro c e s s it in re a l-t im e to m a k e d e c is io n s th a t c a n c h a n g e th e w a y a b u s in e s s is ru n , in s te a d o f w a it in g u n t il it ’s to o la te . It m e a n s m o re e ffi c ie n t m a in te n a n c e a n d t ra in in g . T h is is re d u c in g d o w n t im e , w h ile in c re a s in g p ro d u c t iv it y , a g ilit y a n d s p e e d to m a rk e t .

G e t t i n g s t a r t e d Te c h n o lo g y m a y h a v e b e c o m e in c re a s in g ly in t u it iv e b u t g e t t in g s ta r te d is n 't a lw a y s a s e a s y . W h e n g e t t in g b e g in n in g y o u r jo u rn e y to w a rd s In d u s t r y 4 .0 , c o n s id e r th e fo llo w in g : w h a t d a ta y o u w a n t to c o n n e c t , h o w y o u c a n m a k e s o lu t io n s re p e a ta b le , u s e m a c h in e le a r n in g o r p r e d ic t iv e a n a ly t ic s t o a n a ly s e t r e n d s a n d r e t r ie v e in s ig h t s , h o w y o u w ill d e liv e r re le v a n t in s ig h t s to th o s e w h o n e e d th e m in a c o n su m a b le w a y , a n d w h a t h a p p e n s w h e n y o u d o s p o t s o m e th in g u n u su a l o r in te re s t in g . T r y t o s t r i k e t h e r i g h t b a l a n c e b e t w e e n o f f -t h e -s h e l f a n d c u s to m is e d s o lu t io n s . P r io r it is e s o lu t io n s th a t a re re p e a ta b le f ro m a n in fra s t ru c tu re p e rsp e c t iv e b u t w h ic h o ff e rs a n o v e r th e to p u s e r e x p e r ie n c e fi ts w h a t y o u n e e d .

P la t fo rm s s u c h a s R o c k w e ll A u to m a t io n ’s F a c to r y Ta lk In n o v a t io n S u i t e T M , w h i c h h a s P T C t e c h n o lo g y i n s i d e , i n c lu d e s s p e c i f i c a p p l ic a t io n s a ro u n d r e m o t e m o n it o r in g , c r e a t in g d ig i t a l t w in s w it h A R /V R , a n d a n Io T p la t fo rm t h a t e x t e n d s t o M a n u fa c t u r in g E x e c u t io n S y s t e m s (M E S ), O v e ra ll E q u ip m e n t E f fe c t iv e n e s s (O E E ) a n d p re d ic t iv e m a in te n a n c e to s u p p o r t p ro d u c t iv it y , s u s ta in a b ilit y a n d in te g ra te d s u p p ly c h a in s o lu t io n s . T h e s e e x te n s ib le p la t fo rm s a llo w y o u t o t a p in to a ra n g e o f in -b u ilt a p p lic a t io n s re le v a n t t o y o u r n e e d s to d a y – a n d p o s it io n y o u to a d d in th o s e w h ic h m ig h t b e c o m e u s e fu l d o w n th e lin e . T h e n g e t s ta r te d . D o n 't w o rr y a b o u t g o ld p la t in g it f ro m th e s t a r t . S e e w h a t w o rk s a n d w h a t d o e s n 't . F in d a b a la n c e . Ite ra te . W ith th e h e lp o f th is re m a rk a b le te c h n o lo g y w e c a n g e t th ro u g h th is la te s t c r is is a n d c o m e o u t s t ro n g e r o n th e o th e r s id e .

NEWS & EVENTS

e n te rp r is e t e c h n o lo g y a n d b u s in e s s p ro c e s s m a n a g e m e n t s e r v ic e s th a t e n a b le th e t ra n s fo rm a t io n o f p ro d u c t d e s ig n a n d d e v e lo p m e n t , p ro d u c t io n m a n a g e m e n t , a n d c lie n t s e r v ic e m o d e ls .

“K a ly p s o ’s d e e p ro s te r o f e x p e r ie n c e d c o n s u lt a n t s a n d te c h n o lo g is t s , e x p e r t is e a c ro s s t h e d ig it a l v a lu e c h a in a n d e s t a b lis h e d c u s t o m e r b a s e in k e y g ro w th s e c to r s w ill e n a b le u s t o fu r t h e r a c c e le ra t e o u r c u s t o m e r s ’ C o n n e c t e d E n t e r p r i s e jo u r n e y a n d s u p p o r t R o c k w e l l A u to m a t io n ’s s t ra te g ic o b je c t iv e o f c o n t in u e d d o u b le -d ig it g ro w th in In fo rm a t io n S o lu t io n s a n d C o n n e c te d S e r v ic e s ,” s a id F ra n k K u la s z e w ic z , S e n io r V i c e P r e s id e n t , C o n t r o l P r o d u c t s & S o lu t io n s a t R o c k w e l l A u to m a t io n .

R o c k w e l l A u t o m a t i o n i s b e s t p o s i t i o n e d t o b r i n g I n f o r m a t i o n T e c h n o lo g y (I T ) a n d p la n t f lo o r t e c h n o lo g y (O T ) t o g e t h e r . T h e C o n n e c te d E n te rp r is e c o n v e rg e s p la n t-le v e l a n d e n te rp r is e n e tw o rk s , a n d s e c u re ly c o n n e c t s p e o p le , p ro c e s s e s , a n d te c h n o lo g ie s to d r iv e d ig i t a l t r a n s fo rm a t io n a n d e n a b le s m a r t m a n u f a c t u r in g t h ro u g h o p e ra t io n a l in te llig e n c e , p ro d u c t iv it y a n d r is k m a n a g e m e n t .

T h e a d d e d c a p a b ilit ie s a n d e x p e r ie n c e o f th e K a ly p so te am w ill fu r th e r e n h a n c e R o c k w e ll A u t o m a t io n ’s a b i l i t y t o d e p lo y t e c h n o lo g y a n d d e liv e r e v e n g re a te r v a lu e to c u s to m e rs . “W e a re e x c ite d to b e jo in in g R o c kw e ll A u to m a t io n to b ro a d e n it s e n te rp r is e s o f tw a re c o n s u lt in g a n d in fo rm a t io n a rc h ite c tu re o ff e r in g s a n d e n h a n c e o u r a b ilit y to h e lp o u r c lie n ts h a rn e s s th e p o w e r o f d ig ita l in n o v a t io n to d is c o v e r, c re a te , m a k e a n d s e ll b e t te r p ro d u c ts ,” s a id K a ly p so C E O , G e o rg e Yo u n g .

T h e t r a n s a c t io n is e x p e c t e d t o c lo s e in t h e s p r in g o f 2 0 2 0 , s u b je c t t o c u s to m a r y a p p ro v a ls a n d c o n d it io n s , a n d w ill b e re p o r te d in t h e C o n t ro l P ro d u c ts & S o lu t io n s b u s in e s s s e g m e n t .

2 0 2 0 In d u s t r ia l In n o v a t o r o f t h e Ye a r

I o T B r e a k t h r o u g h r e c o g n i z e s R o c k w e l l A u t o m a t i o n f o r d e l i v e r i n g b r e a k t h r o u g h i n d u s t r i a l I o T i n n o v a t i o n w i t h F a c t o r y Ta lk In n o v a t io n S u i t e

T h e Io T B re a k th ro u g h A w a rd p ro g ram h a s o n c e a g a in h o n o re d R o c kw e ll A u to m a t io n . T h is t im e a ro u n d , w e h a v e b e e n n a m e d t h e 2 0 2 0 In d u s t r ia l In n o v a to r o f t h e Ye a r i n r e c o g n i t i o n o f o u r i n n o v a t i o n a n d c o m m i t m e n t t o c o n n e c t i n g p e o p l e , p ro c e s s e s a n d te c h n o lo g ie s , a n d b r in g in g

th e C o n n e c te d E n te rp r is e to life . L a s t y e a r, w e w e re n am e d a s th e 2 0 1 9 O v e ra ll Io T C o m p a n y o f th e Ye a r.

N o w in it s th ird y e a r, th e Io T B re a k th ro u g h A w a rd s p ro g ram p ro v id e s re c o g n it io n t o in n o v a to r s , le a d e r s , a n d v is io n a r ie s f ro m a ro u n d t h e g lo b e in a ra n g e o f Io T c a te g o r ie s . In to ta l, th e re w e re m o re th a n 3 ,5 0 0 s u b m is s io n s c o m p e t in g fo r m o re t h a n 7 5 a w a rd s in t e n c a te g o r ie s . T h e In d u s t r ia l Io T In n o v a to r o f t h e Ye a r a w a rd c o n s id e r s n o m in e e s f ro m a m o n g a ll Io T c a t e g o r ie s , f ro m sm a r t h o m e t e c h a ll t h e w a y t h ro u g h to in d u s t r ia l s o lu t io n p ro v id e r s . W e w e re c h o s e n b a s e d o n o u r la t e s t “b re a k th ro u g h ” in d u s t r ia l Io T (IIo T ) in n o v a t io n , F a c to r y Ta lk In n o v a t io n S u ite .

R o c k w e ll A u t o m a t io n S t r e n g t h e n s C o n t r o l & V is u a l i z a t io n P o r t f o l io w i t h A c q u is i t io n o f A S E M

R o c k w e l l A u t o m a t i o n a n n o u n c e d i t h a s s i g n e d a n a g re e m e n t t o a c q u ire I t a ly -b a s e d A S E M , S .p .A ., a le a d in g p ro v id e r o f d ig ita l a u to m a t io n te c h n o lo g ie s . A S EM p ro v id e s

a c o m p le te ra n g e o f In d u s t r ia l P C s (IP C s ), H u m a n -M a c h in e In te r fa c e (H M I) h a rd w a re a n d s o ftw a re , re m o te a c c e s s c a p a b ilit ie s , a n d s e c u re In d u s t r ia l Io T g a te w a y s o lu t io n s .

A S E M ’s h i g h -p e r f o r m a n c e a u t o m a t i o n s o lu t i o n s e n a b le T h e C o n n e c t e d E n t e r p r i s e w i t h s m a r t e r t e c h n o l o g y , e n h a n c e d p ro d u c t iv it y , a n d a m o re s e c u re e n v iro n m e n t b y in te g ra t in g sm a r t d e v ic e s , th e c o n t ro l p la t fo rm , a n d d e s ig n a n d o p e ra t io n a l s o ftw a re a ll o n a s in g le n e tw o rk .

“A S EM ’s s t re n g th in th e IP C m a rk e t a n d e x p e r t is e in H M I w ill fu r th e r e x p a n d o u r C o n t r o l a n d V i s u a l i z a t io n h a r d w a r e a n d s o f t w a r e p o r t fo l io a n d e n h a n c e o u r a b i l i t y t o d e liv e r h ig h -p e r fo rm a n c e , in te g ra te d a u to m a t io n s o lu t io n s . A S EM ’s p ro d u c t s w ill p ro v id e o u r c u s to m e rs w ith a h ig h d e g re e o f c o n fig u ra b ilit y fo r th e ir in d u s t r ia l c o m p u t in g n e e d s th ro u g h in n o v a t iv e h a rd w a re a n d s o f tw a re th a t a llo w s t h e m to a c h ie v e fa s t e r t im e to m a rk e t , lo w e r t h e ir c o s t o f o w n e rsh ip , im p ro v e a s s e t u t iliz a t io n , a n d b e t te r m a n a g e e n te rp r is e r is k ,” s a id F r a n W lo d a rc z y k , S e n io r V ic e P re s id e n t , A rc h it e c t u re & S o ftw a re a t R o c kw e ll A u to m a t io n .

“A S EM h a s a le a d in g m a rk e t p o s it io n in Ita ly a n d h a s a b ra n d th a t is s y n o n ym o u s w ith q u a lit y . W e a re d e lig h te d to h a v e th e o p p o r tu n it y to le v e ra g e o u r p io n e e r in g e x p e r t is e in th e d e s ig n a n d p ro d u c t io n o f I n d u s t r ia l P C s a n d in d u s t r ia l s o f t w a re t o b r o a d e n R o c k w e l l A u t o m a t io n ’s C o n t r o l & V i s u a l i z a t i o n o f f e r in g a n d a c c e le r a t e t h e d ig it a l t r a n s fo rm a t io n o f o u r c u s t o m e rs ,” s a id A S E M fo u n d e r, P re s id e n t , a n d C E O R e n zo G u e rra .

T h e t ra n sa c t io n in c lu d e s th e p u rc h a se o f a m in o r it y in te re s t in A S EM h e ld b y K E B G ro u p , G e rm a n y . P o s t -c lo s e , R o c k w e ll A u t o m a t io n w ill m a in t a in A S E M ’s s t r a t e g ic s u p p lie r a n d t e c h n o lo g y p a r t n e r re la t io n s h ip w ith K E B . T h e t ra n s a c t io n is e x p e c te d to c lo s e in t h e s p r in g o f 2 0 2 0 , s u b je c t to c u s to m a r y a p p ro v a ls a n d c o n d it io n s , a n d w ill b e re p o r te d in th e A rc h ite c tu re & S o ftw a re b u s in e s s s e g m e n t .

R o c k w e ll A u t o m a t io n t o B r o a d e n C o n n e c t e d E n t e r p r i s e C o n s u lt in g E x p e r t i s e w i t h A c q u is i t io n o f K a ly p s o

R o c kw e ll A u to m a t io n to d a y a n n o u n c e d th a t it h a s s ig n e d a n a g re e m e n t t o a c q u ire p r iv a t e ly -h e ld K a ly p s o , L P, a U S -b a s e d s o f tw a re d e liv e r y a n d c o n su lt in g fi rm s p e c ia liz in g in

t h e d ig it a l t r a n s fo rm a t io n o f in d u s t r ia l c o m p a n ie s w it h a s t ro n g c lie n t b a s e in life s c ie n c e s , c o n su m e r p ro d u c ts a n d in d u s t r ia l h ig h -t e c h . K a ly p s o o f fe r s a fu ll s u it e o f c o n s u lt in g , d ig it a l in n o v a t io n ,

ASIA PACIFIC 5

W h e t h e r y o u a r e a p h a r m a c e u t i c a l , m e d i c a l d e v i c e o r c o n s u m e r p a c k a g e d g o o d s m a n u f a c t u r e r , a t r a c e a b i l i t y i n f r a s t r u c t u r e t h a t u s e s t h e l a t e s t t e c h n o l o g i e s c a n h e l p

i m p r o v e y o u r t i m e t o m a r k e t , m a n u f a c t u r i n g p r o c e s s e s a n d c o m p l ia n c e .

W e lc o m e t o t h e a g e o f t h e sm a r t in d u s t r ia l p la n t . T h is is w h e re o p e ra t io n s t e c h n o lo g y (O T ) a n d IT c o n v e rg e ; d ig it a l t e c h n o lo g y c o n n e c t s p e o p le , p ro c e s s e s a n d t h in g s in t o a s in g le , s e a m le s s u n i f ie d in f r a s t r u c t u re ; a n d d a t a h e lp s u s id e n t i f y n e w , e x c i t in g o p p o r tu n it ie s . W h ile m o re m a n u fa c tu r in g c o m p a n ie s a re a d o p t in g n e w d a t a -e n a b l i n g t e c h n o l o g i e s , b e c o m i n g a t r u e , s m a r t m a n u fa c tu r in g o p e ra t io n re q u ire s o n e e s s e n t ia l e le m e n t : e n d -to -e n d t ra c e a b ilit y .

A s th e re q u ire m e n ts fo r in d u s t r y re g u la t io n s a n d c o s t s o f w a rra n t y a n d r e f u n d p r o g r a m s c o n t in u e t o e v o lv e , m a n u f a c t u r e r s c a n d iff e re n t ia te th e m se lv e s b y ta k in g a d v a n ta g e o f d ire c t a n d in d ire c t b e n e f it s p ro v id e d b y a t ra c e a b ilit y s y s t e m : im p ro v in g p ro c e s s e s , c o n t ro llin g t h e s u p p ly c h a in , m in im iz in g d e fe c t r is k , n a v ig a t in g re g u la to r y c h a lle n g e s a n d im p ro v in g c u s to m e r s e r v ic e le v e ls .

W ith a t ra c e a b ilit y in fra s t ru c tu re , y o u c a n g a th e r in s ig h t-r ic h d a ta t h a t h e lp s im p ro v e m a n u fa c t u r in g p ro c e s s e s , c o m p lia n c e a n d s u p p ly c h a in m a n a g e m e n t .

Why do smart plants need track-and-trace capabilities? L a r g e a n d m id d le -s i z e d m a n u f a c t u r e r s a r e f a c in g m o u n t in g c h a lle n g e s . F o r e x am p le , p ro d u c t re c a lls a re o n th e r is e . T h e recall process in th e fo o d m a n u fa c tu r in g in d u s t r y is a h ig h ly e x p e n s iv e

o n e , a v e ra g in g m o re t h a n $ 1 0 m illio n in c o s t s t o c o v e r a c t iv it ie s s u c h a s c o m m u n ic a t in g th e re c a ll a c ro s s th e su p p ly c h a in , re t r ie v in g a n d h a n d lin g t h e re c a lle d p ro d u c t , in v e s t ig a t in g t h e e v e n t a n d im p le m e n t in g c o r re c t iv e a c t io n s to p re v e n t re o c c u rre n c e .

A ls o , c o u n te r fe it a n d d iv e r te d g o o d s c o s t s c o m p a n ie s $ 5 0 0 b illio n in U .S . t ra d e , a c c o rd in g to th e World Customs Organization. A n d s im u lta n e o u s ly , o rg a n iz a t io n s a re s t ru g g lin g to im p ro v e c o n t in u a lly o p e ra t io n a l e ffi c ie n c ie s to s ta y p ro fi ta b le a n d c o m p e t it iv e .

W ith o u t c o m p le te e n d -to -e n d t ra c e a b ilit y , it c a n b e d iffi c u lt to s ta y a h e a d o f th e c o m p e t it io n , m e e t d e a d lin e s , k e e p c u s to m e rs h a p p y a n d c o m p ly w ith re g u la t io n s .

A s a n e s s e n t ia l p a r t o f In d u s t r y 4 .0 , c o m p le te t ra c e a b ilit y s t ill ra n k s a m o n g t h e t e c h n o lo g ie s in d u s t r y c o m p a n ie s a re s lo w to a d o p t . H o w e v e r, th e t re n d is p u sh in g to w a rd m o re c o m p a n ie s e m b ra c in g it .

In a s tu d y o f m a n u fa c tu r in g c o m p a n ie s , L N S R e s e a rc h fo u n d th a t w h ile o n ly 2 3 p e rc e n t h a d th e p ro c e s s e s a n d s o f tw a re in p la c e to e n a b le e n d -to -e n d t ra c e a b ilit y , a ro u n d 6 0 p e rc e n t s ta te d th e y p la n to h a v e th e s e p ro c e s s e s a n d s o ftw a re in th e n e x t y e a r. T h is s u g g e s ts m a n u fa c tu re rs re c o g n iz e th e im p o r ta n c e o f p ro d u c t t ra c e a b ilit y .

Discrete part traceability T h e re a re d i f fe re n t w a y s t o a p p ro a c h t r a c e a b i l i t y . D is c re t e p a r t t ra c e a b ilit y — th e u s e o f in d iv id u a l c o m p o n e n t-le v e l m a rk s — is t y p ic a lly t h e m o s t e f fe c t iv e a t e n a b lin g e n d -t o -e n d t r a c e a b ilit y , b e c a u s e e a c h p a r t c a n b e lin k e d w ith in a fin a l a s s e m b ly .

COVER STORY

Single Version of Truth – Beyond

Productivity

6 ASIA PACIFIC

A n u m b e r o f p o p u la r m e t h o d s c a n c re a t e t h e s e d is c re t e p a r t -t r a c e a b i l i t y m a r k s . D ir e c t p a r t m a r k in g is t h e b e s t m e t h o d t o v e r ify re a d a b le m a rk s a re p e rm a n e n t a n d d u ra b le . O th e r in d ire c t m e th o d s , s u c h a s in k je t p r in t in g a n d la b e lin g , a re c o m m o n ly u s e d b e c a u s e th e y o ff e r lo w in it ia l c o s t s .

A m o n g d ir e c t p a r t -m a r k in g e q u ip m e n t , la s e r a n d p in (o r d o t p e e n ) m a r k in g s y s t e m s a r e t h e m o s t p o p u la r, c a p a b le o f c re a t in g p e r m a n e n t m a r k s q u i c k l y o n a v a r i e t y o f m a t e r i a l s . D i r e c t p a r t m a r k in g w i t h la s e r o r d o t -p e e n e q u i p m e n t c a n c r e a t e d u r a b l e b a r c o d e s t h a t c o n n e c t t h e p a r t t o a d a t a b a s e , a l l o w i n g i t t o b e t r a c k e d t h r o u g h p la n t -l e v e l o p e ra t io n s t o f in a l a s s e m b ly , a n d t h e n t r a c e d f o r t h e l i f e o f t h a t p ro d u c t .

T o s u c c e e d a t e n d - t o - e n d t r a c e a b i l i t y w i t h d i s c r e t e p a r t m a r k in g , i t i s im p o r t a n t t o m a r k c o m p o n e n t s a t t h e s o o n e s t p o s s ib le m o m e n t in t h e m a n u fa c t u r in g p ro c e s s . T h is le t s y o u s e e t h e e n t ire life c y c le o f e a c h p a r t a n d m a x im iz e t h e v a lu e o f y o u r d a ta , s o y o u c a n s p o t p ro d u c t io n is s u e s o r t re n d s a n d m a k e p ro a c t iv e im p ro v e m e n ts .

Traceability: From Component to Final AssemblyT r a c e a b i l i t y , t h e p r o c e s s f o r lo c a t in g c o m p o n e n t s a n d t h e i r

a p p ro p r ia t e h is t o r y t h ro u g h o u t t h e i r l i f e , i s a n e s s e n t ia l p a r t o f s m a r t m a n u f a c t u r in g . B y d ig i t a l l y c o n n e c t in g i n d i v id u a l c o m p o n e n t s t o t h e s u b a s s e m b ly , m a jo r a s s e m b ly a n d f in a l a s s e m b ly , m a n u fa c tu re rs c a n :• T ra c k p a r t s th ro u g h th e m a n u fa c tu r in g p ro c e s s .• R e c o rd th e h is to r y o f p a r t ’s a c t iv it ie s .• C re a te a g e n e a lo g y o f p a r t re la t iv e to m a in p a r t n u m b e r a n d

s u b -a s s e m b lie s .• A c h ie v e th e b e n e fi ts o f e n d -to -e n d t ra c e a b ilit y .

Digitization improves time-to-marketS p e e d to m a rk e t is a n in c re a s in g c o n c e rn fo r b io te c h a n d p h a rm a m a n u fa c tu re rs a s p ro d u c t m o v e s fu r th e r a lo n g th e p ip e lin e fro m d is c o v e r y th ro u g h c lin ic a l t r ia ls . A s th e s a y in g g o e s , ‘t im e is o f th e e s s e n c e ’ – th is is p a r t ic u la r ly re le v a n t in th e h ig h ly c o m p e t it iv e life s c ie n c e s in d u s t r y .

L a b o r a t o r y d a t a i s e s s e n t i a l t o c o m m e r c i a l p r o d u c t i o n . C o n s e q u e n t ly , m a k in g la b o r p i lo t p la n t d a t a e a s i ly a c c e s s ib le to d ig ita l a u to m a t io n s y s te m s is c r it ic a l. A modern DCS th a t c a n s c a le f ro m u s e r-fr ie n d ly , s o f tw a re s y s te m s th a t a re r ig h t-s iz e d fo r la b s to c o m p le te ly in te g ra te d p la n t-flo o r s o lu t io n s c a n h e lp .

B a s in g d ig ita l t ra n s fo rm a t io n o n a s c a la b le , m o d e rn D C S d e liv e rs s ig n i f ic a n t b e n e f i t s – in b o t h t h e la b a n d o n t h e p ro d u c t io n fl o o r. A m o d e rn D C S c a n u s e analytics tools to c o n v e r t raw d a ta in t o a c t io n a b le in fo rm a t io n t h a t c a n im p a c t o p e r a t io n a l a n d e q u ip m e n t e ffi c ie n c y fro m th e la b th ro u g h p ro d u c t io n .

ASIA PACIFIC 7

' W h i l e o n l y 2 3 % o f m a n u f a c t u r i n g c o m p a n i e s h a d t h e p r o c e s s e s a n d s o f t w a r e i n p l a c e t o e n a b l e e n d -t o -e n d t r a c e a b i l i t y , a r o u n d 6 0 % p l a n n e d t o h a v e t h e s e i n p l a c e i n t h e n e x t y e a r '

8 ASIA PACIFIC

F o r e x a m p le , t h e s y s t e m c a n a n a ly z e t h o u s a n d s o f d a t a p o in t s in a la b to q u ic k ly u n c o v e r c o r re la t io n s a n d c a u s a t io n s t h a t m a y o t h e rw is e re m a in h id d e n . O n t h e p la n t f lo o r, t h e m o d e rn D C S c a n d e liv e r b a tc h a n d e q u ip m e n t a n a ly t ic s to h e lp k e e p s y s te m s ru n n in g o p t im a lly .

M o s t c r i t i c a l l y , a m o d e r n D C S p r o v i d e s a n e n d - t o - e n d m a n u fa c t u r in g s o lu t io n t h a t la y s t h e fo u n d a t io n fo r electronic batch records (E B R ), v a lid a t io n a n d re g u la to r y c o m p lia n c e .

Data integrity and complianceT h e m o v e t o a n E B R s y s t e m h a s b e e n b e n e f i c i a l f o r m o s t b io p h a rm a c e u t ic a l p ro d u c e rs . B y re p la c in g p a p e r-b a s e d w o rkflo w s w it h c o m p u te r-b a s e d w o r k f lo w s , t h e y h a v e re d u c e d t h e r is k o f h u m a n e r ro r a n d s p e d u p c o m p lia n c e p ro c e s s e s .

H o w e v e r, E B R s y s te m s c a n d o fa r m o re th a n d ig it iz e p a p e r-b a s e d w o rkflo w s a n d re c o rd k e e p in g .

W h e n i n t e g r a t e d i n t o a s c a l a b l e m a n u f a c t u r i n g e x e c u t i o n s y s t e m (M E S ), E B R s b e c o m e m o r e d y n a m ic a n d c a n s u p p o r t y o u r o p e ra t io n s in n e w w a y s . T h is is e s p e c ia lly t ru e a s y o u m o v e y o u r o p e ra t io n s t o w a rd a Connected Enterprise, in w h ic h y o u r p ro d u c t io n a n d b u s in e s s s y s t e m s a re fu lly c o n n e c t e d a n d c a n s h a re in fo rm a t io n s e am le s s ly .

W h e n a n M E S w ith E B R s is b ro u g h t in to a c o n n e c te d e c o s y s te m , it c a n b e g in to a c c e s s e n te rp r is e -w id e in fo rm a t io n , d e liv e r ro le -b a se d in s t ru c t io n to w o rk e rs , a n d p ro v id e e x c e p t io n -b a s e d re p o r t in g . T h is c a n h e lp s p e e d u p y o u r t im e -to -m a rk e t , c u t c o s t s in m u lt ip le a re a s , a n d e a s e o r e v e n im p ro v e y o u r d e m o n s t ra te d c o m p lia n c e .

A n M E S th a t o ff e rs m o d e rn a n d d y n am ic E B R s c a n h e lp a c c e le ra te t im e -t o -m a r k e t in m u lt ip le w a y s . In t h e w o rd s o f o n e p h a rm a p ro d u c e r, “A n E B R s o lu t io n is th e G P S o f m a n u fa c tu r in g o p e ra t io n s . It g u id e s th e u s e r to th e d e s ire d d e s t in a t io n , fi n d s th e s h o r te s t t r ip , a le r t s o n e to d a n g e rs , a n d fe e d s th e m b a c k in re a l t im e .”

Q u a l i t y A s s u r a n c e (Q A ) t e a m s c a n u s e a n E B R ’s r e v i e w -b y -e x c e p t io n f u n c t io n a l i t y t o s p o t d e v ia t io n s m u c h f a s t e r t h a n

s c a n n in g e v e r y re c o rd lin e b y lin e to fin d th e m . T h is c a n s p e e d u p d o c u m e n ta t io n re v ie w t im e s a n d re d u c e h o w lo n g a p ro d u c t m u s t s it in a w a re h o u s e w a it in g fo r re le a s e . I t a ls o c a n im p ro v e b a t c h a c c u ra c y a n d c o n s is te n c y .

In a d d it io n , re a l-t im e in fo rm a t io n a c c e s s c re a te s o p p o r tu n it ie s to s p e e d u p p ro c e s s e s th ro u g h o u t th e p ro d u c t io n c y c le . F o r e x am p le , g a u g e d a t a c a n b e c o l le c t e d a u t o m a t ic a l ly v e r s u s r e q u ir in g a w o rk e r to p h y s ic a lly w a lk to e a c h g a u g e a n d re c o rd th e ir re a d in g s . T h e a b ilit y to c o lle c t a n d re v ie w p ro c e s s in fo rm a t io n a ls o a llo w s y o u to id e n t ify a n d m it ig a te u n n e c e s s a r y ta s k s , s u c h a s re d u n d a n t m a te r ia l c h e c k s .

F u r t h e r m o r e , t h e t im e s a v i n g s o n l y b e c o m e g r e a t e r i n a C o n n e c te d E n te rp r is e . T h e a b ilit y to c o n n e c t y o u r E B R s y s te m to m o b ile d e v ic e s . F o r e x am p le , it c a n g iv e w o rk e rs fa s te r a n d m o re c o n v e n ie n t a c c e s s to in fo rm a t io n a n yw h e re o n th e p la n t fl o o r.

Serialization for end-to-end supply chainW h e th e r y o u a re a p h a rm a c e u t ic a l, m e d ic a l d e v ic e o r C o n s u m e r P a c k a g e d G o o d s m a n u fa c t u re r y o u a re n o w re q u ir e d t o t r a c k a n d t r a c e p ro d u c t s a c ro s s t h e s u p p ly c h a in . In f a c t , a n u m b e r o f c o u n t r ie s a ro u n d t h e w o r ld a re in t h e p ro c e s s o f ro llin g o u t s e r ia liz a t io n -b a s e d a n t i-c o u n te r fe it in g re g u la t io n s . T h e s e in c lu d e t h e E u ro p e a n U n io n 's F a ls i f ie d M e d ic in e s D ire c t iv e , t h e U n it e d S ta te s ' D ru g S u p p ly C h a in S e c u r it y A c t a n d C h in a 's e le c t ro n ic d ru g s u p e r v is io n c o d e re q u ire m e n t .

S e r i a l i z a t i o n u s e s a n u m e r i c o r a lp h a n u m e r i c c o d e k n o w n a s a u n iq u e id e n t i f ic a t io n (U ID ) t o r e a l iz e f u l l track-and-trace capabilities o f a p ro d u c t t h ro u g h o u t t h e s u p p ly c h a in , f ro m it s m a n u fa c t u r in g o r ig in t h ro u g h d is t r ib u t io n c h a n n e ls a n d d o w n to th e p o in t o f s a le . P ro d u c t io n , t ra n s p o r t a t io n a n d p o in t-o f-s a le e v e n t in fo rm a t io n a re re c o rd e d a n d s to re d in a c e n t ra l d a ta b a s e . T h is a llo w s a p ro d u c t to b e a u th e n t ic a te d a s le g it im a te t h ro u g h s o m e th in g a s s im p le a s a q u ic k b a rc o d e s c a n , a n d p e rm it s t h e c o m p le te p ro d u c t e v e n t h is to r y to b e re v ie w e d o r a u d ite d s h o u ld a n is s u e a r is e .

W h ile s e r ia liz a t io n re g u la t io n s v a r y b y c o u n t r y o r re g io n , s o m e g e n e r a l r e q u i r e m e n t s t h a t p h a rm a c e u t ic a l m a n u f a c t u r e r s a r e e x p e c te d to c o m p ly w ith in c lu d e :• T h e a b ilit y to g e n e ra te , a c q u ire a n d m a n a g e a U ID fo r e a c h

s a le a b le ite m .• L in k in g p a c k a g e -le v e l s e r ia l n u m b e r s in p a re n t / c h i ld d a t a

re la t io n sh ip s (fo r e x am p le , p a lle t s to c a s e s , c a s e s to c a r to n s o r c a r to n s to s a le a b le ite m s ).

• S to ra g e o f U ID in fo rm a t io n in a s e c u re d a ta b a s e th a t c a n b e s h a re d w ith t ra d in g p a r tn e rs .

• Va lid a t io n th a t s e r ia liz a t io n d a ta m a tc h e s th e p h y s ic a l p ro d u c t re c e iv e d .

• C o n f i rm a t io n t h a t p ro d u c t s h a v e c o m p le t e a n d a c c u r a t e d o c u m e n ta t io n .

W h i l e s o m e m a n u f a c t u r e r s m a y o p t t o d e v e l o p t h e i r o w n c u s t o m iz e d s e r ia l iz a t io n s y s t e m in a n e f fo r t t o h a rm o n iz e t h e s y s te m w ith t h e ir e x is t in g e q u ip m e n t a n d p ro c e s s e s – t h e re a re s o m e s ig n i f ic a n t l im it a t io n s w it h t h is a p p ro a c h . I t c a n le a d t o

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s u p p o r t is s u e s , p a r t s s h o r t a g e s a n d k n o w le d g e -t r a n s fe r p ro b le m s in t h e lo n g t e rm . T h e t im e a n d e f fo r t n e e d e d t o d e s ig n , t e s t a n d c o m m is s io n a c u s t o m s y s t e m c a n a ls o b e c o s t ly a n d d is ru p t iv e t o o p e ra t io n s .

P h a rm a c e u t i c a l m a n u f a c t u r e r s s h o u ld i n s t e a d c o n s id e r b a s in g t h e ir s y s t e m o n a m o d u la r a n d s c a la b le o f f -t h e -s h e lf c o n t ro l a n d in fo rm a t io n p la t fo rm th a t c a n b e e a s ily in te g ra te d in to th e ir e x is t in g lin e s . S p e c ifi c a lly , b y ta p p in g a s o ftw a re p la t fo rm th a t a ls o o ff e rs M E S a n d E B R c a p a b ilit ie s , a s e r ia liz a t io n s y s t e m c a n h e lp a d d re s s g lo b a l s e r ia liz a t io n re q u ire m e n t s , in c lu d in g n e c e s s a r y d a t a c a p a b ilit ie s a n d h ig h -s p e e d d e v ic e m a n a g e m e n t o f s e r ia liz a t io n c o m p o n e n t s – a ll w h ile m in im iz in g p ro d u c t io n in te r ru p t io n s o r v a lid a t io n b u rd e n s .

A d d it io n a lly , a s e r ia liz a t io n s y s t e m t h a t u s e s a n E le c t ro n ic P ro d u c t C o d e In fo rm a t io n S e r v ic e s (E P C IS )-c e r t if ie d , c lo u d -b a s e d s e r v e r c a n p ro v id e c e n t r a liz e d U ID g e n e ra t io n , m a n a g e m e n t a n d s t o r a g e , a s w e ll a s a c h ie v e in t e ro p e r a b i l i t y w it h m a n u fa c t u r in g a n d b u s in e s s s y s te m s . T h e c lo u d -b a s e d s e r v e r is t h e c e n t ra l c o m m u n ic a t io n s h u b fo r s u p p ly c h a in p a r tn e rs a n d p ro v id e s m o b ile c o n n e c t iv it y , s o p ro d u c t a u th e n t ic a t io n c a n f lo w a ll t h e w a y d o w n to th e c o n s u m e r le v e l v ia ta b le t s o r sm a r tp h o n e s .

Team up with technologyT h e In d u s t r ia l In t e r n e t o f T h in g s (I Io T ) c o n t in u e s t o a d v a n c e a t a ra p id ra te . P h a rm a c e u t ic a l c o m p a n ie s a re t ra n s fo rm in g th e in d u s t r y b y u s in g sm a r t , c o n n e c te d d e v ic e s , a n a ly t ic s , a n d m a c h in e le a rn in g to im p ro v e d ru g m a n u fa c tu r in g p ro c e s s e s a n d d e liv e r b e t te r p a t ie n t o u tc o m e s .

P h a rm a c e u t ic a l c o m p a n ie s h a v e a ls o d ram a t ic a lly in c re a s e d th e u s e o f sm a r t t e c h n o lo g y a n d a u t o m a t io n in t h e ir p ro d u c t io n f a c i l i t ie s t o im p ro v e d r u g q u a l i t y a n d s p e e d in n o v a t io n . A n d m a n y h a v e s t re am lin e d o p e ra t io n s w ith m o d e rn M E S a n d E B R s y s te m s .

B u t a s t h e n u m b e r o f i n t e l l i g e n t d e v i c e s h a s p r o l i f e r a t e d , m a n u fa c tu re rs h a v e s t ru g g le d to u s e th e B ig D a ta g e n e ra te d a c ro s s t h e p la n t fl o o r a n d b e y o n d in t ru ly t ra n s fo rm a t iv e w a y s .

N o w , th a n k s to a d v a n c e d in d u s t r ia l connectivity, data aggregation

a n d a u to m a te d a n a ly t ic s c a p a b ilit ie s , m a n u fa c tu re rs c a n e x a c t m o re v a lu e f ro m m o re d is p a ra te d a ta s o u rc e s fa s te r t h a n e v e r b e fo re .

L e v e r a g in g a s e c u re I Io T in f r a s t r u c t u re , t h e la t e s t c a p a b i l i t ie s c a n q u ic k ly c o n n e c t a ll d a t a th a t ’s im p o r t a n t o n a n a s s e t o r a lin e – a n d im m e d ia te ly m o n ito r p e r fo rm a n c e a s w e ll a s m a k e p re d ic t io n s a b o u t t h a t p e r fo rm a n c e .

C h o o s in g t e c h n o lo g ie s t h a t g iv e y o u r w o r k e r s b e t t e r v is ib i l i t y t o p ro c e s s p a ra m e t e r s in re a l t im e is o n e w a y t o im p ro v e w o r k f lo w s . F o r m a n y b io p h a rm a c e u t ic a l c o m p a n ie s , t h e n e x t s t e p is e n g a g in g in o t h e r d ig i t a l t o o ls t h a t h e lp w o r k e r s u s e d a t a a n d a n a ly t ic s in sm a r te r, m o re im p a c t fu l w a y s .

S p e c ifi c a lly , a u g m e n te d re a lit y (A R ) c a n b e a g am e -c h a n g e r t h a t n o t o n ly e n h a n c e s w o r k fo rc e m a n a g e m e n t , b u t a ls o im p ro v e s q u a lit y , y ie ld a n d t im e -to -m a rk e t .

I n f a c t , m o r e c o m p a n i e s a r e b e g i n n i n g t o u s e A R t o s u p p o r t o p e r a t o r -d r i v e n a c t i v i t i e s . F o r e x a m p le , h e r e ’s o n e -w a y A R c a n d r a m a t i c a l ly im p r o v e s i t u a t io n a l a w a r e n e s s i n y o u r c le a n r o o m . U s in g a m o b i le d e v ic e a n d A R a p p , y o u r o p e r a t o r c a n fo c u s o n a p ie c e o f e q u ip m e n t a n d v ie w c r it ic a l p a ram e te r s s u p e r im p o s e d o n t h e m a c h in e . N o H M I r e q u ire d . T h is s a m e t e c h n o lo g y t h a t m a k e s m o n ito r in g e q u ip m e n t e a s ie r c a n a ls o p ro v id e m a in te n a n c e w o rk e rs w ith d e ta ile d , v is u a l a n d in te ra c t iv e in s t ru c t io n s – a t t h e s it e o f re p a ir.

B u t h o w d o y o u d e c id e w h a t d ig it a l t e c h n o lo g ie s c a n b e s t e n a b le th e w o rk e rs in y o u r p la n t ? A g o o d p la c e to s t a r t is w ith th e w o rk fo rc e c h a l l e n g e s y o u u n d e r s t a n d b e s t . C h a n c e s a r e , y o u d o n ’t n e e d c o m p le x a n a ly t ic s t o d e t e rm in e w h a t t h o s e c h a lle n g e s a re – y o u p ro b a b ly e n c o u n te r t h e m e v e r y d a y .

T h e n , fo c u s o n d e p lo y in g A R o r o t h e r t e c h n o lo g ie s t h a t o f fe r t h e b e s t o p p o r t u n i t y f o r s h o r t -t e rm w in s t h a t d e l i v e r a m e a s u r a b le re tu rn . A n d th a t c a n s c a le a c ro s s m u lt ip le a p p lic a t io n s a n d p la n t s to e s t a b lis h a sm a r t in d u s t r ia l p la n t .

' H o w d o y o u d e c i d e w h a t d i g i t a l t e c h n o l o g i e s c a n b e s t e n a b le w o r k e r s i n y o u r p la n t ? '

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N e w F a c i l i t y f o r P i s t a c h io P r o d u c t io n

New production facility helps meet the growing international demand for pistachios

T o d a y , t h e U .S . i s t h e w o r ld ’s s e c o n d -la r g e s t p i s t a c h io p ro d u c e r – a n d w o r ld w id e d e m a n d c o n t in u e s to g ro w .

O n c e re s e r v e d fo r ro y a lt y , p is t a c h io s h a v e b e c o m e a g lo b a l s n a c k s e n s a t io n . P e o p le a r e h u n g r y fo r t h e g re e n n u t b e c a u s e o f i t s u n iq u e fl a v o r, a lo n g w ith it s n a tu ra l h e a lth a t t r ib u te s . L ik e a lm o n d s , w a ln u ts a n d o th e r n u t v a r ie t ie s , p is ta c h io s a re p a c k e d w ith p ro te in , a n t io x id a n ts a n d fib e r.

W o n d e r fu l P is t a c h io s is a le a d e r in s a t is fy in g w o r ld w id e d e m a n d fo r th is t in y t re a t . T h e c o m p a n y is b a s e d in C a lifo rn ia ’s c e n t ra l S a n J o a q u in Va lle y , th e h e a r t o f A m e r ic a ’s p is ta c h io in d u s t r y . To fl o u r is h , t h e t re e s re q u ire c o o l w in t e r s a n d lo n g , h o t s u m m e r s w it h lo w h u m id it y . T h is la rg e ly lim it s p is t a c h io p ro d u c t io n to th re e p r im a r y p la c e s o n th e p la n e t – Ira n , Tu rk e y a n d C a lifo rn ia .

To d a y , W o n d e r fu l P is t a c h io s a lo n e a c c o u n t s fo r 5 0 p e rc e n t o f t h e g lo b a l p is t a c h io m a r k e t a n d 6 5 p e r c e n t o f t h e d o m e s t ic s a le s . To c o n t in u e to g ro w , W o n d e r fu l P is t a c h io s n e e d e d a n e w fa c ilit y w h e re it c o u ld c o n v e r t m o re raw fru it in to th e ro a s te d – a n d u su a lly s a lte d – sn a c k c ra v e d b y c o n su m e rs a ro u n d th e w o r ld .

Hulling harvestT h e f i r s t s t a g e o f t h e p r o d u c t io n p r o c e s s – h u l l in g – i s t im e -

s e n s it iv e . T h e n u t s c o m e o f f o f t h e t re e s e n c a s e d in a p ro te c t iv e o u te r la y e r, w h ic h m u s t b e q u ic k ly re m o v e d to p re v e n t s p o ilin g . T h a t ’s w h y W o n d e r fu l P is ta c h io s b u ilt th e n e w fa c ilit y in F ire b a u g h , C a lifo rn ia , c lo s e to th e p is ta c h io g ro v e s .

T h e h u llin g s e c t io n o f th e n e w fa c ilit y n e e d e d to b e re a d y in t im e fo r t h e h a r v e s t , w h ic h b e g in s in S e p te m b e r a n d la s t s e ig h t to 1 0 w e e k s . A f t e r h u ll in g , t h e n u t s c a n b e s t o re d fo r t h e y e a r-ro u n d p ro c e s s e s o f s o r t in g , ro a s t in g , s a lt in g a n d p a c k a g in g . C o m p a n y m a n a g e rs p la n n e d to c o m p le te t h o s e s u b s e q u e n t s e c t io n s o n c e th e h u llin g a re a w a s u p a n d ru n n in g .

T h e y p ro je c t e d t h a t m o re t h a n 4 .8 m illio n p o u n d s o f p is t a c h io s w o u ld b e h u lle d e a c h d a y o f t h e h a r v e s t . To h a n d le s u c h a h u g e v o lu m e – e v e n t u a lly a c ro s s t h e e n t ire p ro d u c t io n p ro c e s s – t h e n e w fa c ilit y re q u ire d m a jo r in f ra s t ru c t u re in v e s tm e n t s , in c lu d in g a 3 0 -m e g aw a t t t ra n sm is s io n s u b s t a t io n a n d m ile s o f n a tu ra l g a s p ip e s .

W ith t h a t g ro u n d w o rk u n d e r w a y , t h e c o m p a n y b e g a n p la n n in g th e d e s ig n o f th e h u llin g a n d p ro d u c t io n lin e s .

To m a n a g e t h e e n t i r e p ro c e s s , t h e W o n d e r f u l P is t a c h io s t e a m n e e d e d a c o n t ro l s o lu t io n th e y c o u ld im p le m e n t q u ic k ly , a n d la te r

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CASE STUDY

e x p a n d to in c lu d e c r it ic a l s ta g e s , s u c h a s p a s te u r iz a t io n a n d p re c is e ro a s t in g .

Precise pistachio controlT h e c h o ic e o f a c o n t ro l s o lu t io n c o lla b o ra to r w a s s t ra ig h t fo rw a rd fo r t h e p ro je c t t e am s in c e t h e y ’v e w o rk e d w ith R o c kw e ll A u to m a t io n fo r o v e r 2 0 y e a rs . A lm o s t 1 5 y e a rs a g o , W o n d e r fu l P is t a c h io s b e g a n s t a n d a r d i z i n g o n t h e R o c k w e l l A u t o m a t i o n c o n t r o l p l a t f o r m , in c lu d in g m o to r c o n t ro l c e n te rs (M C C s ).

“In o u r in d u s t r y , t h e t u rn a ro u n d t im e fo r p ro je c t s is v e r y fa s t ,” s a id D o n K lo s te r, e le c t r ic a l e n g in e e r in g m a n a g e r fo r W o n d e r fu l P is ta c h io s . “T h e R o c kw e ll A u to m a t io n c o n t ro l p la t fo rm a llo w s u s to o rd e r a n d in s ta ll c o n t ro lle rs a n d M C C s , a n d s ta r t p ro d u c t io n in a fe w w e e k s .”To c o n t ro l th e 5 0 0 m o to rs p o w e r in g p is ta c h io p ro d u c t io n a t th e n e w fa c ilit y , K lo s te r a n d h is te am d e s ig n e d th e p ro c e s s , c o n fi rm e d th e ir m o to r c o n t ro l n e e d s , a n d o rd e re d A lle n -B ra d le y C E N T E R L IN E 2 1 0 0 M C C s fro m R o c kw e ll A u to m a t io n in b u lk .

T h e sm a r t MCCs, in t e g ra t e d w it h A lle n -B ra d le y P o w e rF le x 7 0 a n d P o w e r F le x 5 2 5 d r iv e s f r o m R o c k w e l l A u t o m a t io n , h e lp p r o v id e f le x ib le c o n t ro l o f p ro d u c t io n . T h e M C C s in c lu d e p re c o n f ig u re d s o f t w a re t h a t g a t h e r s r e a l-t im e p ro d u c t io n a n d d ia g n o s t ic d a t a , t re n d s , c o m p o n e n t h is to r y , w ir in g d ia g ram s , u s e r m a n u a ls a n d s p a re p a r t s .

T h e M C C s p ro v id e s ig n if ic a n t s t a r t u p t im e s a v in g s c o m p a re d t o W o n d e r fu l P is ta c h io s ’ p re v io u s ly in -h o u se b u ilt p a n e ls . A s a lw a y s , th e M C C s w e re fu lly in s p e c te d b e fo re a r r iv a l, e a s in g in s t a lla t io n fo r th e W o n d e r fu l P is ta c h io s te am .

In a d d i t io n , t h e M C C s ’ c e n t r a l i z e d c o n t r o l a n d in t u i t iv e a d d -o n in s t ru c t io n s h e lp p ro v id e a lo w e r to ta l c o s t o f o w n e rsh ip c o m p a re d to th e in -h o u s e p a n e ls b y re d u c in g d o w n t im e a n d t ro u b le sh o o t in g t im e . T h e te am c a n e a s ily m a k e c h a n g e s in th e fi e ld , a n d q u ic k ly a n d s a fe ly m o v e M C C b u c k e ts a s n e e d e d .

T h e M C C s c o m m u n ic a te th e p ro d u c t io n a n d d ia g n o s t ic d a ta v ia a n E th e rN e t / IP n e tw o rk t o A lle n -B ra d le y C o n t ro lL o g ix p ro g ram m a b le a u to m a t io n c o n t ro lle rs (PA C s ) fro m R o c kw e ll A u to m a t io n .

F a c ilit y o p e ra to rs c a n a c c e s s t h e d a t a d ire c t ly f ro m th e c o n t ro lle r s a n d p u ll h is to r ic a l p ro d u c t io n re p o r ts w ith in a n h o u r. T h a t d a ta a llo w s

th e m to q u ic k ly d e te rm in e – a n d if n e c e s s a r y , a d ju s t – p ro d u c t io n v a r ia b le s , s u c h a s d r y e r t e m p e ra tu re s a n d ro a s te r s p e e d s . W ith th e E th e rN e t/IP n e tw o rk c o n n e c t iv it y , W o n d e r fu l P is ta c h io s c a n m o n ito r a ll s y s te m s re m o te ly a n d q u ic k ly re sp o n d to a n y is s u e s .

I n a d d i t i o n , t h e o p e n n a t u r e o f t h e c o n t r o l p la t f o rm a n d t h e E th e rN e t/IP n e tw o rk a llo w e d th e W o n d e r fu l P is ta c h io s te am to e a s ily in s ta ll a n d c o n n e c t O EM -su p p lie d e q u ip m e n t . T h e te am p u rc h a s e d d r y e r s , p a s t e u r iz e r s a n d o t h e r e q u ip m e n t w it h o u t c o n t ro ls , a n d in te g ra te d th e m in to th e C o n t ro lL o g ix p la t fo rm .

Operational efficiencyA f t e r t h e M C C s a r r iv e d , t h e p ro d u c t io n lin e w a s re a d y t o g o l iv e w it h in t h re e w e e k s , ju s t in t im e fo r t h e f a l l h a r v e s t s e a s o n . P re -p ro c e s s in g th e n s ta r te d th e fo llo w in g y e a r, w h ic h e x c e e d e d v o lu m e e s t im a te s b y 1 5 p e rc e n t .

W ith th e c o n t ro l s y s te m ’s re lia b ilit y a n d m o n ito r in g c a p a b ilit ie s , th e n e w fa c ilit y ru n s le a n .

“In 2 0 0 0 , 1 0 0 p e o p le w e re r e q u i r e d t o r u n a f a c i l i t y t h a t w o u ld p ro d u c e 1 .5 m i l l io n p o u n d s p e r d a y ,” s a id P a u l H u g h e s , g e n e r a l m a n a g e r o f c a p ita l p ro je c ts a t W o n d e r fu l P is ta c h io s . “A t th e F ire b a u g h fa c ilit y , 1 0 p e o p le o n s ite m a n a g e p ro d u c t io n o f 5 .6 m illio n p o u n d s p e r d a y d u r in g h a r v e s t s e a so n .”

B y 2 0 2 3 , t h e fa c ilit y w ill h a v e f in is h in g -p ro c e s s in g c a p a b ilit ie s , a n d th e e n t ire b u ild o u t w ill b e c o m p le te d b y 2 0 2 5 .

ASIA PACIFIC 11

C A S E STUDYCASE STUDY

D ig i t a l T r a n s f o rm a t io n in t h e P h a rm a c e u t ic a l In d u s t r y

T h e g lo b a l p h a rm a c e u t i c a l in d u s t r y i s f a c in g in c r e a s in g p re s s u re t o g e t d ru g s t o m a r k e t f a s t e r, w h ile m a in t a in in g c o m p lia n c e a n d d a t a in t e g r i t y . T h e d e m a n d fo r t a rg e t e d ,

s m a lle r v o lu m e p h a rm a c e u t ic a ls a n d p e r s o n a l is e d m e d ic in e s i s g ro w in g a n d th e re fo re , d r iv in g o p e ra t io n s aw a y fro m la rg e -s c a le b u lk p r o d u c t io n t o m u lt ip r o d u c t f a c i l i t i e s t h a t r e q u i r e c o m p l i c a t e d b a tc h in g , fre q u e n t c h a n g e o v e rs a n d m e t ic u lo u s t ra c k in g .

A m o n g th e e n a b lin g te c h n o lo g ie s u n d e rp in n in g th e o n g o in g d ig ita l t r a n s fo rm a t io n in in d u s t r ia l p ro c e s s c o n t ro l w it h in p h a rm a a n d fo o d p ro d u c t io n , M E S s o f tw a re is o n e o f th e fu n d am e n ta l b u ild in g b lo c k s . M E S is c a p a b le o f s ta n d a rd iz in g p ro d u c t io n p ro c e s s e s , w h ile in t e g ra t in g t h e m a n d re n d e r in g t h e m m o re h o m o g e n o u s , w it h a p o s it iv e im p a c t o n c o rp o ra te o rg a n iz a t io n a n d e m p lo y e e p ro d u c t iv it y , a ll w ith o u t a n y n e g a t iv e e ff e c ts o n p ro d u c t io n p ro c e s se s ..

MES improves pharma complianceZ h e jia n g M e d ic in e C o m p a n y (Z M C ) is a g lo b a l b io -p h a rm a c e u t ic a l m a n u fa c tu r in g a n d s te r ile -p a c k in g in d u s t r y e x p e r t , a n in n o v a t iv e p h a rm a c e u t ic a l m o d e l in C h in a ’s e x p o r t b u s in e s s . T h e c o m p a n y re c e n t ly in v e s te d in a n e w M E S s y s te m to m o re e ffi c ie n t ly a n d c o s t-e ff e c t iv e ly p ro d u c e a n t ib io t ic o n F D A ’s d ru g -sh o r ta g e lis t .

T h e s t e r i le p o w d e r fo r in je c t io n p ro je c t w a s Z h e jia n g M e d ic in e C o m p a n y 's f ir s t M E S a p p lic a t io n p ilo t p ro je c t . To m e e t t h e s t r ic t re g u la to r y re q u ire m e n ts in E u ro p e a n d A m e r ic a , Z h e jia n g M e d ic in e C o m p a n y c h o s e R o c kw e ll A u to m a t io n a s it s s t ra te g ic p a r tn e r, u s in g P h a rm a S u ite to e s ta b lis h a B a tc h m a n a g e m e n t a s th e c o re o f th e

M E S s y s te m to e n su re c o m p lia n c e a n d e ffi c ie n t p ro d u c t io n .

R e p la c in g t ra d it io n a l p a p e r re c o rd s a n d d o c u m e n t m a n a g e m e n t , P h a rm a S u it e h e lp e d a c h ie v e t h e g o a l o f 1 0 0 p e rc e n t p a p e r le s s p ro d u c t io n . A f t e r t h e P h a rm a S u it e p ro d u c t io n o rd e r i s i s s u e d , t h e o p e r a t o r p i c k s m a t e r ia l f r o m t h e s t a g in g r o o m . B y u s in g d ig i t a l l a b e l s , P h a rm a S u i t e h e lp s t o a c h ie v e t r a c e a b i l i t y a n d p re v e n t m is t a k e s o r c ro s s c o n t a m in a t io n . T h e d ig i t is in g o f t h e m a n u f a c t u r in g p r o c e s s , c o u p le d w i t h t h e in t e g r a t i o n o f t h e w a r e h o u s e m a n a g e m e n t s y s t e m a n d la b o r a t o r y in fo rm a t io n m a n a g e m e n t s y s t e m , e n a b le s Z M C to p ro d u c e e le c t ro n ic b a t c h re c o rd s .

T h ro u g h in te g ra t io n o f p ro c e s s a u to m a t io n s y s te m s , P h a rm a S u ite c a p t u r e s r e a l p a r a m e t e r s a n d g e n e r a t e s r e a l -t im e r e p o r t s . A p p lic a t io n o f R o c kw e ll A u to m a t io n m o b ile s o lu t io n s fa c ilita te s th e s c a n n in g o f d ig ita l la b e l o f e q u ip m e n t a n d m a te r ia l a n d u p lo a d in g th e re la te d re p o r t to th e M E S b y u s in g g lo b a l ta b le t s .

P h a rm a S u ite m a n a g e s th e p ro d u c t io n e q u ip m e n t a n d in te rm e d ia te fa u lt e q u ip m e n t s ta tu s b y s c a n n in g th e d ig ita l la b e ls o n e q u ip m e n t o r m a t e r ia l, P h a rm a S u it e c o n f irm s t h e c o r re c t e q u ip m e n t t o b e u s e d a n d e n s u re s t h e p ro d u c t io n p ro c e s s is u n d e r c o n t ro l. R e a l-t im e a la rm m o n it o r in g o f t h e p ro d u c t io n p ro c e s s e n s u re s t h a t a b n o rm a l s itu a t io n s c a n b e a t te n d e d to in a t im e ly m a n n e r.

T h e P h a rm a S u ite re c ip e d e s ig n fu n c t io n is c o m p lia n t w ith th e IS A S 8 8 s t a n d a rd p ro v id in g a m o d u la r, g r a p h ic a l a n d c o n f ig u r a b le

12 ASIA PACIFIC

Biotech and pharma companies are looking to intelligent, connected operations as a way to remain competitive and better serve those who rely on their products.

CASE STUDY

ASIA PACIFIC 13

s o lu t io n . U s in g th e la te s t v ir tu a liz a t io n te c h n o lo g y , th e M E S a n d S C A D A s y s t e m s a re t h re e p h y s ic a l s e r v e r s – g re a t ly r e d u c in g h a r d w a r e a n d m a i n t e n a n c e c o s t s w h i l e im p r o v i n g t h e I T m a n a g e m e n t e ffi c ie n c y .

P h a rm a S u i t e a c c u r a t e ly a n d c o m p le t e ly s t o r e s t h e r e a l-t im e d a t a a n d p ro d u c t io n p ro c e s s in fo rm a t io n in t h e d a t a b a s e a n d c re a te s a b a c k-u p . A c c e s s m a n a g e m e n t a n d a u d it t ra il c a p a b ilit y h e lp s to e n su re th a t a ll d a ta c re a t io n , e n t r y a n d m o d ifi c a t io n a re c o n t ro lle d a n d t ra c e a b le .

R e p l a c i n g t h e t r a d i t i o n a l p a p e r r e c o r d s a n d d o c u m e n t s m a n a g e m e n t , P h a rm a S u i t e a c h ie v e d 1 0 0 p e r c e n t p a p e r le s s d u r in g th e p ro d u c t io n p ro c e s s . T h e n e w s o lu t io n a ls o e n h a n c e d q u a lit y b y a u to m a t in g d a ta h a n d lin g , re d u c in g th e r is k o f e r ro rs s u c h a s m is in te rp re t in g o r in c o r re c t ly e n te r in g d a ta . In a d d it io n , th e P h a rm a S u ite M E S re d u c e d c o s t s . T h e s e c o s t s a v in g s in c lu d e f iv e t o 1 0 p e rc e n t la b o r s a v in g s ; 4 6 t o 7 5 p e rc e n t re d u c t io n in b a t c h p ro d u c t re v ie w c y c le t im e ; a n d 5 0 p e rc e n t re d u c t io n in m a n a g e m e n t re v ie w c y c le t im e .

T h e n e w M E S e n a b le d Z M C t o t h r iv e in a h ig h ly c o m p e t it iv e g lo b a l p h a rm a c e u t ic a l in d u s t r y w h ile re m a in in g c o m p lia n t in a n e v e r-t ig h te n in g re g u la to r y e n v iro n m e n t .

Digital transformation: Endusers’ perspectivesA t a r e c e n t r o u n d t a b le d is c u s s io n in I t a ly t i t le d “T h e D ig i t a l T r a n s f o r m a t i o n : C h a l l e n g e s a n d O p p o r t u n i t i e s f o r t h e M a n u f a c t u r in g In d u s t r y ,” R o c k w e l l A u t o m a t io n w a s a b le t o d is c u s s th e c h a lle n g e s o f d ig it a liz a t io n o f p ro d u c t io n p ro c e s s e s . A n d , a b o v e a ll, h o w d o t h e y a t t r ib u t e n e w t e c h n o lo g ic a l a n d b u s in e s s v a lu e s to th e s e c h a lle n g e s .

L u c a P e z z a n o fro m IB I L o re n z in i, A le s s ia C r iv e lli fro m Fa rm a c e u t ic i F o rm e n t i - G r ü n e n t h a l, D a v id e C a s c e lla f ro m Id e a 7 5 , T iz ia n o P e t ru c c ia n i f ro m M o lt e n i F a rm a c e u t ic i a n d S ig f r id o Ve lic o g n a f r o m I b s a F a r m a c e u t i c i I t a l i a – i n c o l l a b o r a t i o n w i t h t h e R o c kw e ll A u to m a t io n I t a ly t e am – a re w o rk in g in t h e d ire c t io n o f 4 .0 p r o d u c t io n s y s t e m s , t h r o u g h t h e im p le m e n t a t io n o f M E S , serialization solutions (b a s e d o n s t a n d a rd PharmaSuite software) a n d process technologies in t h e ir v a r io u s f a c i l i t ie s a c ro s s th e c o u n t r y .

M E S s o f tw a re w a s d e f in e d a s o n e o f t h e fu n d am e n ta l b u ild in g

b l o c k s b y Idea75 a n d Farmaceutici Formenti (G r u p p o G r ü n e n t h a l ) . I n Molteni Farmaceutici a n d IBI Lorenzini , s e r ia l i z a t io n w a s f i r s t d e p lo y e d a s a r e g u la t o r y r e q u i r e m e n t b u t w a s t h e n p ro g re s s iv e ly t r a n s fo rm e d w it h t h e a d o p t io n o f P h a rm a S u it e s o f t w a re f ro m R o c k w e ll A u t o m a t io n in o rd e r t o im p le m e n t n e w p ro c e s s m a n a g e m e n t p r a c t ic e s w it h in t h e i r fa c ilit ie s – m a x im iz in g a n d o p t im iz in g th e c o lle c t io n a n d a n a ly s is o f d a ta a lo n g th e e n t ire s u p p ly c h a in .

T h e im p o r t a n c e o f t h e in t e g ra t io n , m a n a g e m e n t a n d in t e g r it y o f d a ta a lo n g th e e n t ire s u p p ly c h a in is a fu n d am e n ta l a sp e c t fo r IBSA F a rm a c e u t ic i It a lia to o .

In th is a n d o th e r e x am p le s , p ro c e s s te c h n o lo g ie s , lo g ic a l c o n t ro l o f p ro d u c t io n l in e s a n d e n v iro n m e n t a l c o n d it io n m o n it o r in g m u s t g u a r a n t e e m a x im u m s t a b i l i t y a n d s a f e t y a lo n g w i t h s c a la b ilit y a n d im p ro v e d in te ra c t io n s w ith lin e o p e ra to rs .

F o r p h a rm a c e u t ic a l p ro d u c e rs , it is e s s e n t ia l to h a v e s t a b le a n d s c a la b le p la t fo rm s th a t n o t o n ly w o rk to g e th e r to p re v e n t d a t a lo s s , b u t a ls o fa c ilita te d a ta a n a ly s is a n d c o m p a r is o n a s q u ic k ly a s p o s s ib le .

B a s e d o n t h e fe e d b a c k f ro m th e s e e n d u s e rs , it is o b v io u s t h a t t h o s e w h o a re s e e k in g to c re a te Sm a r t In d u s t r y 4 .0 p ro d u c t io n p ro c e s s e s m u s t a ls o d e p lo y e v e r m o re in te g ra te d , ra p id a n d s lim -lin e d a ta m a n a g e m e n t u s in g “c o g n it iv e ” a u to m a t io n p ro c e s s .

A s t h e s e I t a lia n e n d u s e r s h a v e c o n f irm e d t o u s , in t h e w o r ld o f In d u s t r y 4 .0 , t h e re a re a n d a lw a y s w ill b e im p ro v e d fo rm s o f s ta n d a rd iz a t io n a n d o p e n , in te g ra te d p la t fo rm s .

To c o n t in u a lly d r iv e t h is d ig it a l t r a n s fo rm a t io n , i t is t h e re fo re n e c e s s a r y to in v e s t in s o ftw a re a n d te c h n o lo g ie s th a t re n d e r d a ta a n d in fo rm a t io n m o re u s e a b le a n d t r a n s fe ra b le t o t h o s e w h o t ru ly n e e d t h e m , w it h a c lo s e r c o n n e c t io n b e tw e e n IT a n d O T , p ro v id in g s u p p o r t fo r d e c is io n s w ith o u t p re c e d e n ts .

A b o v e a ll, it ’s im p o r ta n t to re m e m b e r th a t digital transformation in v o lv e s t h re e f u n d a m e n t a l e le m e n t s : p e o p le , p ro c e s s e s a n d te c h n o lo g ie s .

N o M o r e B a d B a t c h e s f o r B a k in g C o m p a n y

New batch management system reduces downtime and improves dough quality for global snack manufacturing company

A la rg e g lo b a l b ra n d s n a c k m a n u fa c tu re r s u ff e re d e x c e s s iv e p ro d u c t io n lo s s e s a n d in fe r io r fi n a n c ia ls a t o n e p la n t fo r fa r t o o lo n g . L o w y ie ld , p o o r d o u g h q u a li t y a n d u n p la n n e d d o w n t im e a ll w e re c re a te d b y th e p ro b le m a t ic b a tc h c o n t ro l

s y s te m fo r it s 1 2 m ix in g s ta t io n s a n d in g re d ie n t d e liv e r y s y s te m s .

To c o m p lic a t e t h in g s , t h e e x i s t in g c o d e w a s in a c c e s s ib le a n d “l o c k e d -d o w n ” a s a p r e c a u t i o n o f t h e p r o p r i e t a r y s o f t w a r e . F ru s t ra t io n m o u n te d d a ily a s e v e r y o n e k n e w w h a t th e p ro b le m w a s b u t re c o g n iz e d th e im p lic a t io n s o f u n ta n g lin g it w h ile m a in ta in in g th e b u s in e s s ’ p a c e .

T h e y s e e m e d t o h a v e o n ly t w o o p t io n s . O n e , d o n o t h in g a n d c o n t in u e t o s u f fe r t h e ills o f t h e a g in g s y s t e m , p o o r p ro d u c t io n , in e ffi c ie n c y “ta x ” a n d la c k o f fl e x ib ilit y to u p g ra d e . Tw o , s h u t d o w n e a c h o f th e 1 2 m ix in g s ta t io n s o n e b y o n e o v e r a lo n g a n d d raw n -o u t t ra n s it io n p e r io d , re p la c in g a n d te s t in g c o d e in e a c h o f th e 1 4 in d iv id u a l p ro g ram m ab le a u to m a t io n c o n t ro lle rs (PA C s ) a n d h o p e , a f te r s e v e ra l m o n th s o f c h a n g e , th a t p ro d u c t io n fo r th e e n t ire p la n t w o u ld im p ro v e .

B u t w h a t if th e re w e re a th ird o p t io n ? W h a t if a ll th e c o d e fo r th e 1 4 PA C s , a ll th e h u m a n -m a c h in e in te r fa c e (H M I) s ta t io n s a n d a n e w b a t c h m a n a g e m e n t s o lu t io n c o u ld b e w r it t e n a n d t e s t e d o n a ru n n in g s y s te m — o ffl in e ?

T h is c o u ld s h o r te n d o w n t im e s ig n ifi c a n t ly , c re a te c o n fid e n c e in th e n e w c o d e a n d re d u c e th e r is k s to th e b u s in e s s . T h is w o u ld m it ig a te u n p re d ic ta b le re su lt s , e s c a la t in g c o s t s a n d a n in d e fin ite s h u td o w n .T h e s n a c k c o m p a n y a s k e d R o c kw e ll A u to m a t io n S o lu t io n P a r tn e r Polytron t o e m u la t e t h e m ix in g s y s t e m s b e fo re in s t a l la t io n t o o p e ra t e t h e m v ir t u a lly a n d t r y “w h a t -if ” s it u a t io n s . T h is g a v e t h e m a n u f a c t u re r c o n f id e n c e in t h e n e w b a t c h m a n a g e m e n t a n d c o n t ro l s y s te m so th e c o m p a n y c o u ld s h u t d o w n th e e n t ire m ix in g a re a — e ff e c t iv e ly , th e e n t ire p la n t .

T h e c o m p a n y t h e n c o u ld re p la c e a ll o f t h e m ix in g s t a t io n a n d in g re d ie n t d e l iv e r y s y s t e m p ro g r a m m in g k n o w in g p ro d u c t io n w o u ld s ta r t b a c k u p ju s t a fe w d a y s la te r.

Replacing locked codeT h e e x is t in g b a tc h c o n t ro l s y s te m h a d b e e n in s ta lle d s e v e ra l y e a rs e a r l ie r a n d c o n t a in e d lo c k e d -d o w n , p ro p r ie t a r y c o d e t h a t s t i l l h a d b u g s ; th e p la n t c o u ld n ’t s u p p o r t o r m o d ify th e s y s te m o n it s o w n . T h e s n a c k b a k e r h a d to re ly o n a s u p p lie r w h o w a s to u g h to s c h e d u le , w a s h u n d re d s o f m ile s a w a y a n d c am e a t a h ig h c o s t .

T h is s n a c k m a k e r re q u ire d a n o p e n , s ta n d a rd a p p ro a c h to p ro v id e th e a b ilit y to o p e ra te a n d m a in ta in its o w n sy s te m s w ith its o w n s ta ff .

R e p l a c i n g l o c k e d c o d e p r e s e n t e d i t s o w n c h a l l e n g e s :1 . W i t h n o d o c u m e n t a t i o n f o r t h e e x i s t i n g s y s t e m ,

P o l y t r o n a n d t h e s n a c k b a k e r h a d t o r e d e f i n e h o w t h e s y s t e m w a s o p e r a t i n g a n d r e v e r s e e n g i n e e r a l l t h e c o d e b e f o r e s t a r t i n g o n t h e n e w c o d e .

2 . T h e s y s t e m in t e g r a t o r ’s t e a m o f e n g in e e r s a n d t h e p la n t ’s b a t c h in g s y s t e m s e x p e r t s w o r k e d s i d e b y s i d e , t a p p in g in t o t h e o p e r a t io n s s u p e r v is o r s ’ e x p e r t is e a n d k n o w le d g e t o v e r i f y t h e a p p ro p r ia t e t e c h n o lo g y t r a n s fe r w a s a p p lie d s o t h e n e w c o d e d e f in i t io n c a p t u r e d c r i t i c a l in fo rm a t io n .

3 . C re a t in g a d e t a ile d d e s c r ip t io n o f h o w th e n e w FactoryTalk Batch s y s t e m f r o m R o c k w e l l A u t o m a t io n w o u ld o p e r a t e w a s e s s e n t ia l t o m a k in g s u re t h e s n a c k b a k e r w o u ld n ’t lo s e t im e re t r a in in g i t s o p e ra t o r s o n a c o m p le t e ly n e w s y s t e m .

4 . U s in g t h e d e t a i le d d e s c r ip t io n , t h e e x is t in g ControlLogix p r o c e s s o r s w e r e r e p r o g r a m m e d u s i n g P l a n t PA x L i b r a r y o f O b j e c t s f o r s t a n d a r d i z a t i o n o f c o d e .

5 . T h e FactoryTalk View HMI s c r e e n s h a d t o l o o k a n d o p e r a t e t h e s a m e . T o a c c o m p l i s h t h i s , e x i s t i n g H M I s w e r e r e p la c e d w i t h t h in c l i e n t s u s in g A C P ThinManager a n d F a c t o r y T a l k V i e w . S e q u e n c e s h a d t o w o r k j u s t a s t h e y d id p r e v io u s ly . A n d a l l t h e b a t c h r e c ip e s h a d t o b e

CASE STUDY

14 ASIA PACIFIC

fo llo w e d p re c is e ly t o m e e t s t r ic t fo o d q u a lit y s t a n d a rd s .6 . T h e e x i s t i n g W i n d o w s P C s i n t h e f a c i l i t y w e r e

r e p l a c e d w i t h t h i n c l i e n t s u s i n g A C P T h i n M a n a g e r .7 . I n t e g r a t i o n w i t h e a c h o f t h e s u b s y s t e m s

h a d t o b e r e w r i t t e n t o f l a w l e s s l y i n t e g r a t e e a c h c r i t i c a l s y s t e m i n t o t h e e n t i r e s o l u t i o n .

A n o th e r P o ly t ro n te am c re a te d a s im u la t io n m o d e l o f th e p la n t ’s e n t ire m ix in g s y s te m : 1 2 m ix s ta t io n s a n d a lm o s t tw o d o ze n d r y a n d liq u id in g re d ie n t d e liv e r y s u b s y s te m s . A ll in a ll, m o re th a n 7 0 0 d e v ic e s w e re m o d e le d . W h e n c o n n e c te d to th e PA C s , H M Is a n d n e w b a t c h m a n a g e m e n t s o lu t io n , t h e b a k in g c o m p a n y h a d a fu lly o p e ra t io n a l b a tc h s y s te m th a t c o u ld b e te s te d o ffl in e .

P o ly t ro n u s e d s im u la t io n s o f tw a re w it h P la n t PA x t o s im u la t e I O d r i v e r s u s i n g E t h e r N e t / I P a n d O P C s p e c i f i c a l l y m a d e f o r t h e R o c k w e l l A u t o m a t i o n L o g i x a n d R S L o g i x E m u la t e a u t o m a t io n p la t fo rm s . T h e t e a m c o u ld t e s t t h e n e w c o n t ro l s y s t e m w i t h a d y n a m ic , r e a l i s t i c s im u la t i o n o f t h e i r p la n t .

T h e te am s p e n t d a y s v e r ify in g re c ip e s a n d o p e ra t in g s c e n a r io s , m a n u a l a n d a u t o m a t e d s e q u e n c e s a n d e v e n p o t e n t ia l f a u lt s a n d re c o v e r y s te p s . A fte r p a r t ic ip a t in g in s o m e o f th is e x te n s iv e t e s t in g , t h e p la n t m a n a g e r fe l t c o n f id e n t in s h u t t in g d o w n t h e p la n t w it h lit t le r is k o f m is s in g t h e s t a r t p ro d u c t io n d a t e .

New dough flowing

T h e b a k in g c o m p a n y e x te n d e d it s a lre a d y p la n n e d T h a n k sg iv in g s h u td o w n b y ju s t o n e d a y . P o ly t ro n h a d to d e liv e r a n d h a v e th e p la n t b a c k in p ro d u c t io n M o n d a y m o rn in g .

T h e p la n n in g , m o d e lin g a n d t e s t in g p a id o f f. A c c o rd in g t o a re p re s e n t a t iv e f ro m th e b a k in g c o m p a n y , “T h e a b ilit y t o ru n a fu ll p re c h e c k w a s in v a lu a b le a n d e lim in a te d th e g u e s s w o rk a n d u n c e r t a in t y a t s t a r t -u p . T h e n e w c o d e w a s in t ro d u c e d in to th e s y s te m in a s e am le s s fa sh io n , w h ic h re su lte d in a n o n -t im e s ta r t-u p .”

B y n in e o ’c lo c k M o n d a y m o rn in g , o n ly f iv e d a y s la t e r, a ll t h e s y s t e m s h a d b e e n c l e a n e d , a n d n e w d o u g h w a s f l o w in g .

T h e c o m p le te ly n e w b a t c h m a n a g e m e n t a n d c o n t ro l s o lu t io n m e t a ll e x p e c ta t io n s : n o u n p la n n e d d o w n t im e , te c h n ic ia n s n o w h a d a c c e s s t o e x am in e c o d e a t w ill, a n d q u a lit y s p e c if ic a t io n s w e re o n ta rg e t .

• E v e n b e t te r, d o w n t im e d e c re a s e d b y 2 5 p e rc e n t a n d d o u g h q u a li t y im p ro v e d 3 0 p e r c e n t , m e a n in g n o b a d b a t c h e s .

• O p e ra to rs w e re u p a n d ru n n in g in n o t im e . O n e e v e n a s k e d a w e e k a f t e r t h e p ro g ram s h a d b e e n sw it c h e d , “S o , w h e n a r e w e g o in g t o m a k e t h e c h a n g e s t o t h e s y s t e m ?

CASE STUDYCASE STUDY

ASIA PACIFIC 15

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LET' S KEEP THINGS SMOOTH.

ENSURE QUALITY.DELIVER CONSISTENCY.

SPEKTRON INDUSTRIALUV DISINFECTION SYSTEMSFOR FOOD & BEVERAGE.

16 ASIA PACIFIC

S im p li f y in g B io p h a rm a c e u t ic a l P r o d u c t io n w i t h S in g le -U s e S y s t e m s

Biomanufacturers are looking for technologies that can make their production systems more flexible

and efficient – single-use technology can help

T h e a d v a n c e m e n ts in s in g le -u s e a n d m o b ile t e c h n o lo g y h a v e m a d e b io p h a rm a c e u t ic a l p r o d u c t io n m o r e f le x ib le a n d p r o f i t a b le . A n t ib o d ie s , p ro t e in s , v a c c in e s , c e ll t h e ra p y , a n d g e n e t h e r a p y a r e a l l e x a m p l e s o f m o l e c u l e s t h a t c a n b e n e f i t f r o m b e i n g m a n u fa c tu re d in fu lly s in g le -u s e , e n d to e n d p ro c e s s e s .

S in g le -u s e s y s t e m s h e lp t o lo w e r o v e r a l l o p e r a t i n g c o s t s b y r e d u c i n g t h e t im e re q u ire d t o p e r fo rm c le a n in g a n d c le a n in g v a l id a t io n – d e c r e a s in g a n a ly t i c a l q u a l i t y c o n t ro l c o s ts a n d im p ro v in g fa c ilit y u t iliz a t io n t im e . T h e y a ls o a llo w m a n u fa c tu re rs to m o re e a s i ly a n d q u ic k ly c h a n g e o v e r f r o m o n e p ro d u c t t o a n o t h e r, o r f ro m o n e b a t c h t o a n o th e r b a tc h .

G i v e n t h e s i g n i f i c a n t c o s t s i n v o l v e d w h e n d e v e l o p i n g a n d p r o d u c i n g b i o p h a r m a c e u t i c a l m e d i a t i o n s , b i o m a n u f a c t u r e r s a r e l o o k i n g f o r te c h n o lo g ie s th a t c a n m a k e th e ir p ro d u c t io n s y s te m s m o re f le x ib le , s c a la b le a n d q u ic k e r to im p le m e n t .

A s a r e s u lt , s in g le -u s e t e c h n o lo g ie s h a v e e v o lv e d to b e c o m e a m a in s t re am a p p ro a c h fo r a c h ie v in g p ro d u c t iv it y . F ro m s in g le -u s e b io re a c to rs a n d d is p o s a b le c h ro m a to g ra p h y c o lu m n s , to c o m p le te s in g le -u s e w o rk fl o w s a n d b i o m a n u f a c t u r i n g f a c i l i t i e s , G E H e a l t h c a r e h a s b e e n a t t h e f o r e f r o n t o f s in g le -u s e in n o v a t io n .

Streamlining process control and automationGE Healthcare Life Sciences h a s b e e n

c o l la b o r a t in g w i t h R o c k w e l l A u t o m a t io n t o s t r e a m l i n e t h e p r o c e s s c o n t r o l s a n d a u t o m a t io n o f i t s b io re a c t o r s , F le x F a c t o r y p ro d u c t io n l in e s , a n d s h ip p in g c o n t a in e r -b a s e d , c l e a n - r o o m u n i t s i t o p e r a t e s w o r ld w id e .

"B io t e c h n o lo g ie s a n d b io p h a rm a c e u t i c a l p r o c e s s e s a f f e c t a l l o f o u r l i v e s—f r o m re m o v in g la c t o s e f r o m m ilk t o im p ro v in g b re a d a n d c h e e s e t o c re a t in g f lu v a c c in e s , p re g n a n c y te s t s a n d d ia b e t ic th e ra p ie s . W e 're a ls o u s in g t h e m t o d e v e lo p a p ro t e in t h a t c a n h e lp fig h t lu n g c a n c e r b y m a k in g c a n c e r c e lls a ta rg e t , w h ic h a llo w s th e b o d y 's n a tu ra l w h ite c e lls to a t ta c k th o s e c a n c e r c e lls , w h ile le a v in g re g u la r lu n g t is s u e u n h a rm e d ," s a id K e v in S e a v e r, g e n e ra l m a n a g e r, B io p ro c e s s A u t o m a t i o n a n d B i o p r o c e s s D i g i t a l , G E H e a l t h c a r e . "I t 's e s t im a t e d t h a t b y 2 0 2 2 , b io p h a rm a c e u t ic a ls w ill m a k e u p a b o u t 3 0 p e rc e n t o f th e p re s c r ip t io n d ru g m a rk e t ."

B o t h u p s t r e a m a n d d o w n s t r e a m m a n u f a c t u r i n g p r o c e s s e s b e n e f i t f r o m s i n g l e -u s e s y s t e m s , p a r t i c u l a r l y w h e n m a n u f a c t u r e r s a r e p r o d u c i n g b u f f e r s o lu t io n s o r c e ll-c u ltu re m e d ia . F u r th e rm o re , b io p ro c e s s in g a p p l ic a t io n s in c lu d e la rg e -m o le c u le a n d s m a l l-m o le c u le p r o c e s s e s . S o , w h ile t r a d it io n a l m e d ic in e s l ik e P ro z a c a r e c o m p o u n d e d f r o m m o l e c u l e s w i t h l e s s t h a n 6 0 a t o m s , b i o p h a rm a c e u t i c a l s l ik e in s u lin h a v e m o le c u le s w it h h u n d re d s o f a t o m s , m o n o c l o n a l a n t i b o d i e s h a v e m o re t h a n 1 0 ,0 0 0 a t o m s , a n d f lu v a c c in e s h a v e m o re t h a n 1 0 0 ,0 0 0 . T h is c o m p le x i t y m a k e s d e v e lo p m e n t a n d u p s t r e a m a n d d o w n s t r e a m p r o d u c t io n o f t h e s e n e w e r b io p h a rm a c e u t ic a ls in c r e a s in g ly c o m p le x a n d c o s t ly .

"B e c a u s e o f t h e s e e x p e n s e s , t h e r e a r e e f fo r t s t o d e v e lo p 'b io -s im i la r ' m e d ic in e s t h a t c o s t le s s . P lu s , w h e n p a t e n t s e x p i r e ,

o t h e r m a n u f a c t u r e r s s t a r t p r o d u c i n g t h e m ," e x p la in e d S e a v e r. "O t h e r d r iv e r s o f c h a n g e in t h e b io p h a rm a c e u t ic a l m a r k e t in c lu d e p e r s o n a l i z e d m e d ic in e , lo c a l i z e d m a n u fa c tu r in g , a n d o th e r n e w te c h n o lo g ie s ."S e a v e r a d d e d th a t th e in d u s t r y is c h a lle n g e d b y d o w n w a r d p r i c e p r e s s u r e s , t im e -t o -m a r k e t p re s s u re s , a n d a d a p t in g q u ic k ly t o c h a n g in g m a r k e t d e m a n d s . "F o r e x a m p le , c e llu la r th e ra p ie s h a v e o n ly b e e n a v a ila b le fo r fo u r o r fi v e y e a rs , a n d n o w g e n e th e ra p ie s a re q u ic k ly e m e rg in g ," h e e x p la in e d . "H o w e v e r, b e c a u s e i t c a n t a k e s e v e n y e a r s a n d $ 1 .2 b illio n to $ 1 .7 b illio n to d e v e lo p a n e w d ru g , p h a rm a c e u t ic a l m a n u fa c tu re rs n e e d to b u ild th e ir p la n t s fo u r o r fi v e y e a rs a h e a d o f t im e . C o n se q u e n t ly , if w e c a n im p le m e n t a s in g le -u s e b io p ro c e s s fa c ilit y in ju s t o n e y e a r o r 1 8 m o n t h s , i t a l lo w s o u r b io p h a rm a c e u t i c a l m a n u fa c tu re rs to p u t o ff d e c is io n s to g o in to p ro d u c t io n , w h ic h c a n s a v e m o n e y a n d t im e , a n d a v o id a lo t o f fru s t ra t io n ."

Collaboration yields benefitsS e a v e r re p o r te d th a t G E H e a lth c a re 's 3 0 -y e a r c o l la b o r a t io n w i t h R o c k w e l l A u t o m a t io n h a s a l r e a d y y i e l d e d m a n y b e n e f i t s , b u t t h e ir la t e s t c o lla b o ra t io n o n o p t im iz in g t h e b io r e a c t o r s in i t s F le x F a c t o r y l in e s , w h ic h c a n b e d e p lo y e d in it s K U B io p re fa b r ic a te d s h ip p in g -c o n ta in e r c le a n ro o m s , h a v e e v e n m o re p o te n t ia l b e n e fi ts .

"W h e n w e ru n a t y p ic a l 2 ,0 0 0 -lite r b io re a c to r, th e re c a n b e 3 0 0 p ip e s , lin e s a n d c o n n e c t io n t h a t m u s t b e m a d e e v e r y t im e w e r u n a b a t c h ," e x p la in e d S e a v e r. "D e v e lo p in g a n a p p lic a t io n lik e th is c a n s ta r t sm a ll w ith o n e t y p e o f p r o c e s s c o n t r o l, b u t i t m a y n e e d a n e n t ire ly d i f fe re n t , m o re e x p e n s iv e t y p e o f c o n t ro l w h e n w e s c a le u p . W e n e e d e d a b e t te r, m o re c o n s is te n t w a y to s c a le u p , a n d th is is a n o th e r re a s o n w h y w e 're p a r tn e r in g w ith R o c kw e ll A u to m a t io n ."

TECHNOLOGY WATCH

ASIA PACIFIC 17

S e a v e r a d d e d t h e p h a r m a c e u t i c a l i n d u s t r y w a s t e s a b o u t $ 5 0 b i l l i o n p e r y e a r in in e f f ic ie n t m a n u fa c t u r in g , a n d s o b io p h a rm a c e u t i c a l p la y e r s a r e t r y in g t o u n lo c k is o la te d d a ta th a t c a n 't b e a c c e s s e d , r e d u c e t h e s u b s t a n t i a l t im e s p e n d o n g a t h e r in g a n d c le a n in g d a t a , a n d a t t h e s a m e t im e p ro t e c t a g a in s t c y b e r s e c u r i t y p ro b e s , in t ru s io n s a n d a t ta c k s .

"O n e F l e x F a c t o r y g e n e r a t e s a b o u t o n e te ra b y te o f d a ta p e r d a y ," s a id S e a v e r. "S o w e a ls o n e e d to w a s te le s s o f th a t d a ta , a n d d o m o re w ith it ."

Choosing the right technologiesG E H e a l t h c a r e 's s t r a t e g y f o r a d d r e s s in g t h e s e m u l t i p l e c h a l l e n g e s i n i t s b io p h a rm a c e u t i c a l a p p l i c a t io n i s c a l le d "F ig u ra te ," a n d it in c lu d e s ta k in g a d v a n ta g e o f a u t o m a t io n , f le x ib i l i t y , e f f i c ie n c y a n d c o n fid e n c e . S e a v e r a d d e d th a t a u to m a t io n 's b e n e fi ts fo r b io p ro c e s s e s in c lu d e :• O p t im i z e d u p t im e d u e t o s y s t e m

re d u n d a n c y ;• R e d u c e d m a in te n a n c e a n d t ra in in g b y

u s in g a c o m m o n fram e w o rk ;• Y ie ld o p t im iz a t io n w i t h c e n t r a l i z e d

d a ta t re n d in g a n d a la rm in g ; a n d ,• R e d u c e d r e g u la t o r y e x p o s u r e w i t h

G A M P -p r o v e n a n d C F R -c o m p l i a n t d e s ig n s .

"W h e n e v e r w e h e a t , a g i t a t e , a d d a i r o r o t h e r w i s e p r o c e s s t h e s e $ 1 -2 m i l l i o n b a t c h e s , w e n e e d re d u n d a n t s e r v e r s a n d re d u n d a n t p o w e r th a t c a n sw a p o v e r if o n e s y s te m fa ils ," a d d e d S e a v e r. "T h e s e s o lu t io n s a ls o h e lp w ith a c h ie v in g c o m m o n t ra in in g a n d re d u c in g o u r re g u la to r y e x p o su re .”

To d e v e lo p a n d p u t it s F ig u ra te p ro g ram in p la c e , S e a v e r re p o r t e d t h a t G E H e a lt h c a re a d o p t e d R o c k w e ll A u t o m a t io n 's P la n t PA x

p r o c e s s s y s t e m a n d s o f t w a r e a n d G E 's U n ic o rn so ftw a re to a u to m a te it s b io p ro c e s s e q u ip m e n t ; m a d e t h e ir d a t a a v a i la b le b y in te g ra t in g it w ith a p p lic a b le m a n u fa c tu r in g e x e c u t io n s y s t e m (M E S ) a p p lic a t io n s a n d e le c t r o n ic b a t c h r e c o rd s (E B R ); a n d a ls o p ro v id e d it to c lo u d -c o m p u t in g s e r v ic e s .

G E H e a lt h c a re 's F le x F a c t o r y l in e s in c lu d e i t s m e d i a a n d b u f f e r p r e p a r a t i o n , c e l l c u ltu re p ro d u c t io n , h a r v e s t in g , p u r ifi c a t io n , v i r a l c le a r a n c e , s t e r i le f i l t r a t io n a n d b u lk fo rm u la t io n p ro c e s s e s . A ll o f t h e s e c a n b e c o m b in e d in m o d u la r K U B io c le a n -ro o m s h ip p in g c o n t a in e r s , a n d G E H e a l t h c a r e p r e s e n t l y h a s 6 3 o f t h e s e m o d u l a r p ro d u c t io n fa c ilit ie s ru n n in g w o r ld w id e .

"W e 're a b le t o d e liv e r a F le x F a c to r y in s id e a K U B io in o n e y e a r to 1 8 m o n th s b e c a u s e w e c a n d o a l l t e s t i n g , e l e c t r o n i c s , p r e -v e r i f ic a t io n a n d p re -v a l id a t io n , a n d h a v e t h e s e u n i t s r e a d y t o g o ," s a i d S e a v e r . "T h is a l lo w s o u r m a n u fa c t u re r s t o a d ju s t d e p lo ym e n t a s n e e d e d ."

S e a v e r a d d e d th a t b e n e fi ts fro m it s F ig u ra te p r o g r a m a l s o i n c l u d e 1 0 -2 0 p e r c e n t i n c r e a s e s i n p r o d u c t i o n t h r o u g h p u t , a v a i l a b i l i t y a n d p r o d u c t i o n e m p l o y e e e ffi c ie n c y , a s w e ll a s 5 -3 0 p e rc e n t d e c re a s e s i n e n e r g y u s e , s c r a p m a t e r i a l , b a t c h re le a s e t im e , m a in te n a n c e , a n d d o w n t im e in v e s t ig a t io n s .

To in te g ra te t h e s e g a in s e v e n m o re f irm ly , S e a v e r re p o r t e d t h e G E H e a lt h c a re is a ls o w o rk in g w ith R o c kw e ll A u to m a t io n a n d P TC t o c re a t e a u g m e n te d re a lit y (A R ) v e r s io n s o f t h e s e t o o ls . F o r e x a m p le , i t s o p e ra t o r s c a n u s e A R im a g e c a p t u r e , d i s p la y a n d m a n ip u la te im a g e s th a t s h o w p H , d is s o lv e d o x y g e n , c a r b o n d io x id e , c o n t r o l c a b in e t p e r fo rm a n c e a n d o th e r c ru c ia l p a ram e te rs m o r e q u i c k ly . P T C C h a lk s o f t w a r e e v e n

a llo w s o p e ra to rs a n d s u p e r v is o r to m a rk u p im a g e s to p o in t o u t d e ta ils th a t n e e d to b e a d d re s s e d .

Staying ahead of the innovation curveB illy S is k , L i fe S c ie n c e s In d u s t r y M a n a g e r E M E A , R o c k w e l l A u t o m a t i o n , e x p l a i n s t h a t t h e r e ’s b e e n a la r g e in c r e a s e in t h e l e v e l o f c o m p l e x i t y i n t h e b i o p h a r m a m a n u fa c tu r in g in d u s t r y .

R o c k w e l l A u t o m a t i o n h a s d e v e l o p e d s o l u t i o n s f o r t h e s i n g l e -u s e m a r k e t t o h e lp in c re a s e th e s p e e d to m a rk e t fo r e n d u s e r s , re d u c e r is k a n d in c re a s e re g u la t o r y c o m p l i a n c e . W e d o t h i s t h r o u g h o u r te c h n o lo g y .

I n a t y p i c a l s i n g l e -u s e e n v i r o n m e n t , e v e r y t h i n g i s b u i l t a r o u n d E t h e r N e t / IP. W e a d o p t e d E t h e r N e t / IP a s p a r t o f t h e s in g le -u s e s o lu t io n b e c a u s e i t a l lo w s fo r e q u ip m e n t m o b i l i t y a n d t h e a d d it io n o f n e w a n d d iff e re n t e q u ip m e n t .

A R c a n b e a g a m e - c h a n g e r f o r b io p h a rm a c e u t ic a l c o m p a n ie s th a t n o t o n ly e n h a n c e s w o rk fo rc e m a n a g e m e n t , b u t a ls o im p ro v e s q u a lit y , y ie ld a n d t im e -to -m a rk e t .

In fa c t , m o re c o m p a n ie s a re b e g in n in g to u s e A R to s u p p o r t o p e ra to r-d r iv e n a c t iv it ie s . N e w a d v a n c e m e n t s i n A R a n d a r t i f i c i a l i n t e l l i g e n c e (A I ) c a n g u i d e o p e r a t o r s th ro u g h a s e q u e n c e o f ta s k s a n d th e n v e r ify th a t th e c o r re c t c o n n e c t io n s w e re m a d e – a ll fro m a h a n d h e ld d e v ic e .

F u r t h e r m o r e , t h a t v e r i f i c a t i o n c a n b e s to re d in th e e le c t ro n ic b a tc h re c o rd (E B R ) – a lo n g w ith s u p p o r t in g p ic to r ia l o r v id e o d o c u m e n ta t io n .

Addressing today’s batch manufacturing challenges require a modern approach – leveraging the latest technologies to uncover new competitive advantages

T h e w o r ld is c h a n g in g a n d a s a re s u lt s o is m a n u fa c tu r in g . To d a y ’s d y n a m ic m a n u f a c t u r in g in d u s t r y p r e s e n t s m u lt ip le c h a l le n g e s : c o n t ro l c o s t s , m it ig a te r is k s , a n d s e iz e e v e r y o p p o r tu n it y to g a in a c o m p e t it iv e e d g e . F o r m a n y c o m p an ie s , th is m e a n s p ro d u c t io n a re a s m u s t d r iv e o u t in e ff ic ie n c ie s th a t a re h o ld in g th e m b a c k w ith b o ld a p p ro a c h e s . T h is re q u ire s in fo rm e d d e c is io n m a k in g , d a t a -d r iv e n e x p o su re o f in e ffi c ie n c ie s , a n d a t re m e n d o u s am o u n t o f c o lla b o ra t io n . I n d e e d , o r g a n iz a t io n s t h a t e m b r a c e t o d a y ’s r a p id ly a d v a n c in g te c h n o lo g ie s s ta n d to u n c o v e r n e w c o m p e t it iv e a d v a n ta g e s .

A s c o m p a n ie s t a c k le t h e s e c h a lle n g e s , t h e y m u s t re v ie w n e w a n d m o d e rn a p p ro a c h e s to e s t a b lis h e d p ro c e s s e s t ra d it io n a lly u s e d in b a tc h in g a p p lic a t io n s . Fa c ilit ie s th a t a re c o n s t ra in e d b y r ig id s y s te m s c a n n o t a d a p t to c h a n g in g e q u ip m e n t c o n d it io n s o v e r t im e o r t a k e a d v a n ta g e o f c o m m o n w o rkflo w s a s th e y s c a le p ro c e d u re s fro m p ilo t a re a s to v o lu m e p ro d u c t io n .

Modern batch delivers valueE a c h p r o d u c e r h a s d i v e r s e b a t c h p r o c e s s i n g n e e d s f r o m s im p le , s in g le -v e s s e l , s in g le -p r o d u c t p r o d u c t io n t o c o m p le x p ro d u c t io n s y s te m s . W h ile b a tc h p ro c e s s in g n e e d s d iff e r b e tw e e n m a n u fa c t u re r s , t h e ir fo c u s r e m a in s t h e s a m e – t o m a k e b e t t e r in fo rm e d b u s in e s s d e c is io n s .

A d v a n c e m e n ts in te c h n o lo g y c a n a d d o p p o r tu n it y a n d r is k s fro m b o t h in t e r n a l a n d e x t e r n a l s o u rc e s t h a t e x p a n d w it h e a c h n e w c o n n e c t io n o f sm a r t th in g s . W ith e a c h o p p o r tu n it y c o m e s a d d e d th re a ts c a p a b le o f d is ru p t in g b a tc h o p e ra t io n s , s a fe t y , p ro d u c t iv it y , a n d th e a b ilit y to h e lp p ro te c t a s s e t s , m a c h in e r y , a n d in fo rm a t io n . A m o d e rn b a tc h s y s te m m u s t u t iliz e a d e s ig n fo r s e c u r it y a p p ro a c h th a t s e c u re s p ro d u c t io n s y s te m s a n d in te lle c tu a l p ro p e r t y y e t h e lp s th e p la n t m e e t u p t im e e x p e c ta t io n s .

T h e s y s t e m m u s t s im u l t a n e o u s l y m a k e d a t a a v a i l a b l e f o r c o n t in u o u s im p ro v e m e n t a n a ly s is w h ile p ro t e c t in g t h e in t e g r it y o f d a ta . T h is d a ta c a n th e n b e le v e ra g e d in re g u la to r y a n d q u a lit y c o n t ro l re p o r t in g . T h e C o n n e c te d E n te rp r is e fu lly in c o rp o ra te s th e a b ilit y to b o th c a p ita liz e o n o p p o r tu n it ie s a n d p ro te c t a g a in s t r is k s th ro u g h a m o d e rn b a tc h s y s te m .

I n f a c t , a m o d e r n b a t c h s o lu t io n i s a k e y c o m p o n e n t o f The Connected Enterprise. I t h e lp s y o u v i e w r e a l -t im e d a t a o n m a n u fa c t u r in g p ro c e s s e s , c o m p a re p e r fo rm a n c e a c ro s s p la n t s , q u i c k l y s c a l e p r o d u c t i o n u p o r d o w n , a n d m a n a g e e n e r g y

c o n s u m p t i o n . A C o n n e c t e d E n t e r p r i s e p r o m o t e s s e a m le s s c o lla b o ra t io n a n d in te g ra t io n e n a b lin g th e p o w e r o f re a l-t im e d a ta to h e lp im p ro v e p ro d u c t iv it y .

Making it scalableS c a la b ilit y is n o t ju s t a b o u t s u p p o r t in g te c h n o lo g ie s th a t p o s s e s s t h e a b i l i t y t o c o n t ro l b o t h sm a ll a n d la rg e s y s t e m s . I t i s a b o u t u n d e rs ta n d in g th e n e e d a n d a p p ly in g th e r ig h t te c h n o lo g y ra th e r t h a n s t a r t in g w ith a p ro d u c t a n d t r y in g to u s e it fo r a ll s o lu t io n s . A s c a la b le o f fe r in g o f s o lu t io n s c a n r e s u lt in m o re p ro d u c t iv e o p e ra t io n s b y lo w e r in g th e e n g in e e r in g a n d m a in te n a n c e c o s t s .

I n s o m e i n s t a n c e s , s e r v e r a n d n e t w o r k i n f r a s t r u c t u r e a n d t h e i r a s s o c i a t e d s e c u r i t y n e e d s a r e a b a r r i e r t o a p p ly b a t c h s o f tw a re o n sm a ll o r s t a n d a lo n e s y s t e m s . In t h e a b s e n c e o f t h is in fra s t ru c tu re , u s e rs s h o u ld s t ill b e a b le to im p le m e n t e s ta b lis h e d in d u s t r y s t a n d a rd c o n t ro l t h ro u g h in t e g r a t e d s t a t e m o d e l a n d s t a t e p r o p a g a t io n c o n t r o l . C o n v e r s e ly , t o s im p ly d r i v e b a t c h m a n a g e m e n t m o d e ls d o w n to th e c o n t ro lle r, w h ic h m a y p ro v id e s o m e b e n e fi t , m a y n o t b e th e r ig h t s o lu t io n e ith e r.

T h e b e n e f i t s o f a s u p e r v i s o r y b a t c h m a n a g e m e n t s y s t e m fo r c o m p le x a r c h i t e c t u r e s c a n n o t b e o v e r s t a t e d . W h e n c o m p le x a rc h ite c tu re s re su lt in c o n t ro l b e in g d is t r ib u te d am o n g s e v e ra l u n it s in m u lt ip le c o n t ro lle rs , a c e n t ra liz e d s y s te m c a n p ro v id e th e m o s t lo g ic a l a n d c o n s is te n t c o o rd in a t io n o f th e p la t fo rm .

A d v a n c e d c o n t r o l technologyC o n t r o l s y s t e m s i n a m o d e r n b a t c h s y s te m m u s t b e d e s ig n e d s o t h a t t h e r e s p o n s iv e n e s s c a n b e m a x im iz e d w h e n th e p ro c e s s c a l l s f o r i t . M a k in g a l lo w a n c e s fo r u n d e r p e r fo rm a n c e in a r e a s s u c h a s t h e l a t e n c y o f a s t a t e t r a n s it io n u lt im a t e ly c o s t s t im e , p r o d u c t q u a l i t y , a n d o v e r a l l p ro fi ta b ilit y . In m a n y c a s e s it is p re fe r re d to m o v e th e s e q u e n c in g c o n t r o l c l o s e r t o t h e p h y s i c a l e q u i p m e n t t o b e t t e r c o n t r o l s e n s it iv e s te p s , m a in ta in s e c u r it y a n d im p ro v e th e re lia b ilit y o f t h e s y s te m .

T h e p r o c e s s i n g p o w e r o f t o d a y ’s c o n t r o l l e r s p r o v i d e u n p re c e d e n te d s p e e d a n d fu n c t io n a lit y c o m p a re d t o t h e ir e a r ly p re d e c e s s o r s . T h e re a re m a n y a p p lic a t io n s t h a t t r y t o le v e r a g e th e s e c o n t ro lle r c h a ra c te r is t ic s fo r ra p id re s p o n s e o r h ig h a v a ila b le p e r fo rm a n c e a rc h it e c t u re s in a b a t c h p ro c e s s . A m o d e rn b a t c h s o lu t io n m u s t b e a b le to t a k e a d v a n ta g e o f t h e s e c a p a b ilit ie s fo r p h a s e a n d s t a te t ra n s it io n c o n t ro l – w ith o u t a b a n d o n in g p ro v e n t e c h n o lo g ie s a n d m e th o d s t h a t w e re t ra d it io n a lly o n ly a v a ila b le w ith s e r v e r-c la s s s y s te m s .

APPLICATION PROFILE

M o d e r n B a t c h S o lu t io n s H e lp S o lv e T o d a y ’s M a r k e t C h a l le n g e s

18 ASIA PACIFIC

' T h e p r o c e s s i n g p o w e r o f t o d a y ' s controllers provide u n p r e c e d e n t e d s p e e d a n d f u n c t i o n a l i t y compared to their predecessors'

ASIA PACIFIC 19

Find your competitive advantageT h e c h a n g in g e x p e c t a t io n s o f t o d a y ’s w o r k fo r c e w it h t h e f a s t -m o v in g p a c e o f t e c h n o lo g y p re s e n t s a s h if t f ro m r ig id t e c h n o lo g y s p e c i a l i s t t o w a r d s o p e r a t i o n a l g e n e r a l i s t s . T o d a y ’s w o r k f o r c e d e m a n d s th e e a s y a d o p t io n o f to o ls t h a t h a v e in tu it iv e w o rk fl o w s . A m o d e rn a p p ro a c h m u s t n o t o n ly a d d re s s t h e s e c h a lle n g e s w ith t e c h n ic a l c a p a b i l i t ie s b u t d o s o w h i le m a in t a in in g t h e s e c u r i t y , in te g r it y , a n d re lia b ilit y o f t h e p ro d u c t io n s y s te m .

M e e t in g c o n s t a n t ly c h a n g in g c o n s u m e r d e m a n d r e q u i r e s t h e a b ilit y t o in t u it iv e ly m a n a g e re c ip e s a n d w o r k f lo w s a n d p ro v id e a c c e s s to c r it ic a l p ro d u c t io n in fo rm a t io n . A m o d e rn b a tc h s y s te m c a n h e lp y o u fi n d y o u r c o m p e t it iv e a d v a n ta g e b y : R e d u c in g w a s te a n d e n e r g y u s e ; Im p ro v in g y ie ld ; O p t im iz in g c o n s u m p t io n o f m a t e r ia ls ; E n a b lin g fa s t a n d e f f ic ie n t p ro d u c t c h a n g e o v e r ; D r iv e q u a lit y im p ro v e m e n t s .

A d v a n c e s in b a t c h t e c h n o lo g y p ro v id e t h e c a p a b ilit y t o im p ro v e w o r k f l o w s , r e d u c e p r o c e d u r a l s t e p s i n a t a s k , a n d s im p l i f y c o n f i g u r a t i o n . T h i s a p p l i e s t o b o t h t h e d e s i g n a n d r u n t im e e n v iro n m e n t s . T h e re u s e o f c o d e t e m p la t e s a n d s o f tw a re -b a s e d c h a n g e m a n a g e m e n t t o o ls a re n o lo n g e r o p t io n s o r p e r k s , b u t a n e s s e n t i a l p a r t o f t h e b a t c h c o n t r o l p r o c e s s . T h e R o c k w e l l A u t o m a t io n F a c t o r y T a lk B a t c h s o f t w a re o f fe r s a n in t u i t iv e a n d s c a la b le , b ro w s e r-b a s e d in te r fa c e th a t a d a p t s a c ro s s sm a r tp h o n e s t o t a b le t s a n d P C s . U s e r s c a n a c c e s s r e a l-t im e in fo rm a t io n a n d in te ra c t w ith t h e ir p ro c e s s f ro m th e p la n t fl o o r to t h e p ro d u c t io n o ffi c e th ro u g h a c o n s is te n t u s e r in te r fa c e .

R e d u c e d t im e t o e x e c u t e r o u t in e t a s k s b e n e f i t s e v e r y o n e in a p r o d u c t io n e n v i r o n m e n t b y u s in g m o b i le d e v ic e s . O p e r a t io n s m u s t n o lo n g e r b e b o u n d to c o n t ro l ro o m s o r fi x e d t e rm in a ls t o e x e c u te a c t iv it ie s s u c h a s a la rm a c k n o w le d g e m e n t , m a n u a l d a t a e n t r y , o r b a s ic e q u ip m e n t o p e ra t io n s . To t r u ly m a x im iz e s y s t e m

p e r fo rm a n c e , t h e a c t io n s a n d a c t iv it ie s o f p e o p le in te ra c t in g w ith th e s y s te m m u s t a ls o b e o p t im iz e d . G a in s in p ro d u c t iv it y m a y t a k e m a n y fo rm s s u c h a s b y u s in g s c a la b le g r a p h ic s t h a t a re d e v ic e in d e p e n d e n t , s im p le u s e r in t e r fa c e s t h a t re d u c e t h e n u m b e r o f c lic k s re q u ire d t o n a v ig a t e , a n d t h e s u p p o r t o f m u l t i p le la n g u a g e s a g lo b a l w o rk fo rc e .

M a n u f a c t u r e r s d e p e n d o n b a t c h o p e ra t io n s fo r fl e x ib ilit y a n d p e r fo rm a n c e t h a t c a n b e t a i l o r e d t o m e e t s p e c i f i c b u s in e s s a n d p ro d u c t io n g o a ls – q u a lit y , d e liv e r y a n d , m o s t o f a ll, re s p o n s iv e n e s s c a n b e y o u r c o m p e t it iv e a d v a n t a g e . T h e Rockwell Automation batch portfolio i s u n iq u e ly p o s i t io n e d t o le v e r a g e m u lt ip le t e c h n o lo g ie s t o p ro v id e a f le x ib le c o n t ro l e n v i r o n m e n t t o h e lp y o u m e e t y o u r d e m a n d s f o r i n c r e a s e d p r o d u c t io n a n d im p ro v e d y ie ld s . I t i s t im e t o r e t h in k w h a t a m o d e rn b a tc h s y s te m c a n d o fo r y o u .

' It 's time to rethink what a m o d e r n batch system c a n d o f o r you'

P R O D U C T & S O L U T I O N FOCUSPRODUCT & SOLUTION FOCUS

P r in t e r s a n d o t h e r in d u s t r ia l o p e ra t o r s c a n im p ro v e t h e ir e n e rg y e f f ic ie n c y a n d re d u c e m a c h in e c o m p le x it y w it h a n e w f a n le s s v e r s i o n o f t h e Allen-Bradley Kinetix VPC

continuous-duty servo motor fro m R o c kw e ll A u to m a t io n .

T h e n e w m o t o r u s e s t h e s a m e i n t e r i o r p e r m a n e n t m a g n e t t e c h n o lo g y a s t h e o r ig in a l fa n v e r s io n to h e lp o p e ra to r s a c h ie v e b e t te r p e r fo rm a n c e a n d h ig h e r e n e rg y e ffi c ie n c ie s .

T h e n e w m o to r a c h ie v e s IE 5 e n e rg y e ffi c ie n c y ra t in g s . A d d it io n a lly , b y r e m o v in g t h e f a n t h e m o t o r f u r t h e r r e d u c e s w i r i n g a n d c o m p o n e n t s , s a v e s e v e n m o re o n e n e rg y c o s t s , a n d is id e a l fo r a p p lic a t io n s lik e p r in t in g th a t a re s e n s it iv e to a ir fl o w d is tu rb a n c e s .

T h e V P C fam ily o f m o to rs re d u c e s to rq u e r ip p le , w h ic h t ra n s la te s in to sm o o th e r ro ll-to -ro ll w e b -h a n d lin g p ro c e s s e s c r it ic a l fo r h ig h -q u a lit y p r in t in g , te n s io n in g a n d o th e r a p p lic a t io n -sp e c ifi c ta s k s .

20 ASIA PACIFIC

E n g in e e rs c a n u s e th e n e w Allen-Bradley 140MP Motor Protection Circuit Breakers f ro m R o c kw e ll A u to m a t io n to s im p lify m o to r p ro te c t io n .

T h e c irc u it b re a k e rs , a ls o k n o w n a s m o to r-p ro te c t iv e sw it c h in g d e v i c e s , c a n b e m o u n t e d o n A l le n -B r a d le y 1 0 0 -C o r 1 0 0 -K c o n ta c to rs to c re a te a tw o -c o m p o n e n t m o to r s ta r te r. T h e d e v ic e s p ro v id e m a g n e t ic s h o r t-c irc u it p ro te c t io n a n d th e rm a l-o v e r lo a d p ro te c t io n u p to 3 2 A , a n d in te r ru p t in g ra t in g s u p to 1 0 0 kA a t 4 0 0 V.

T h e c irc u it b re a k e rs a re e n a b le d b y U L a p p ro v a l fo r u s e in g ro u p in s t a lla t io n . T h is t y p e o f in s t a lla t io n c a n re d u c e p a n e l s p a c e , in s ta lla t io n a n d w ir in g t im e , a n d o v e ra ll c o s t s b y e lim in a t in g th e n e e d fo r in d iv id u a l b ra n c h s h o r t -c irc u it p ro t e c t iv e d e v ic e s fo r e a c h m o to r c irc u it .

O u t s id e N o r th A m e r ic a , t h e s e d e v ic e s m e e t t h e IE C 6 0 9 4 7 -4 -1 re q u ire m e n t fo r m o to r p ro te c t iv e sw it c h in g d e v ic e s . T h e y a ls o m e e t th e IE C 6 0 9 4 7 -2 re q u ire m e n t fo r c irc u it b re a k e rs

N e w M o t o r P r o t e c t io n C i r c u i t B r e a k e r s O ff e r S p a c e , T im e a n d C o s t S a v in g s

N e w F a n le s s K in e t ix V P C S e r v o M o t o r D e l iv e r s E n e r g y S a v in g s

P R O D U C T & S O L U T I O N FOCUSPRODUCT & SOLUTION FOCUS

ASIA PACIFIC 21

N e w S ig n a l in g D e v ic e s M e e t G lo b a l R a t in g s , C e r t ifi c a t io n s f o r H a z a r d o u s L o c a t io n s

N e w A lle n -B ra d le y 855X Hazardous Location Signaling Devices c a n h e lp in d u s t r ia l o p e ra to rs m e e t th e la te s t g lo b a l h a z a rd o u s -lo c a t io n ra t in g s a n d c e r t ifi c a t io n s . T h e s ig n a lin g

d e v ic e s in c lu d e h o r n s , b e a c o n s a n d c o m b in a t io n h o r n -a n d -b e a c o n u n it s .

In m o s t c a s e s , t h e s e n e w 8 5 5 X d e v ic e s (S e r ie s B ) a r e d ro p -in re p la c e m e n ts fo r th e o r ig in a l 8 5 5 X d e v ic e s (S e r ie s A ). H o w e v e r, th e re d e s ig n e d p o r t fo lio a ls o o ff e rs a d d it io n a l a d v a n ta g e s :• T r ip le c e r t ifi c a t io n in a s in g le u n it : T h e n e w 8 5 5 X p ro d u c ts a re

a ll c U L u s , AT E X /IE C E X a n d C la s s /Z o n e c e r t ifi e d , s o th e y c a n b e a p p lie d g lo b a lly .

• E a s i ly c u s t o m iz a b le t o a p p l ic a t io n n e e d s : T h e n e w 8 5 5 X p ro d u c t s fe a tu re tw o c o n d u it e n t r y o p t io n s fo r f le x ib ilit y in p o w e r c o n n e c t io n s to s u it th e a p p lic a t io n re q u ire m e n ts . T h e b e a c o n ’s c o lo r c a n b e c h a n g e d q u ic k ly a n d e a s ily in th e fi e ld b y s im p ly re p la c in g th e b e a c o n le n s w ith th e d e s ire d c o lo r, w ith o u t a ff e c t in g th e d e v ic e ’s in g re s s p ro te c t io n ra t in g .

T h e n e w 8 5 5 X s t a n d -a lo n e m u l t i f u n c t i o n L E D b e a c o n a n d c o m b in a t io n r a d ia l s o u n d e r / L E D b e a c o n f e a t u r e r u g g e d y e t lig h tw e ig h t , c o r ro s io n -f re e c o n s t ru c t io n . T h e y a ls o h a v e in g re s s p ro t e c t io n c e r t if ie d t o U L T y p e 4 /4 X /1 3 , IP 6 6 /6 7 , m a k in g t h e m s u it a b le fo r w e t a n d h a rs h in d u s t r ia l e n v iro n m e n t s in th e o il a n d g a s , fo o d , p a p e r, m in in g a n d w a s te w a te r-t re a tm e n t in d u s t r ie s .

N e w P U R a n d P V C S in g le -C a b le O p t io n s E a s e In s t a l la t io n , M a in t e n a n c e

In d u s t r ia l o p e ra to rs c a n s p e e d u p in s t a lla t io n t im e s a n d re d u c e p a r t s in v e n to r ie s b y u s in g a s in g le c a b le to p ro v id e b o th p o w e r a n d fe e d b a c k b e tw e e n d r iv e s a n d m o to rs . A n d

n o w , o p e ra to rs h a v e m o re s in g le -c a b le o p t io n s a t t h e ir d is p o s a l w it h t h e re le a s e o f n e w A lle n -B ra d le y 2090 single cables t h a t in c lu d e h a lo g e n -fre e P U R a n d P VC o p t io n s .

T h e h a lo g e n -fre e o p t io n s a re id e a l fo r a p p lic a t io n s lik e fo o d a n d b e v e ra g e , w h e re u s e rs w a n t to re d u c e e x p o su re to to x in s , a n d fo r a p p lic a t io n s lo o k in g to m e e t IE C 6 0 7 5 4 -1 .

T h e c a b le s a re d e s ig n e d fo r s y s t e m s t h a t u s e K in e t ix 5 5 0 0 a n d 5 7 0 0 s e r v o d r iv e s , K in e t ix VP -S e r ie s s e r v o m o to rs a n d K in e t ix VPA R e le c t r ic c y lin d e rs . T h e c a b le s a ls o h a v e a sm a lle r b e n d ra d iu s fo r c o n t in u o u s -fl e x a n d s ta t ic a p p lic a t io n s a n d a re a v a ila b le in a w id e ra n g e o f c a b le AW G s , t y p e s a n d c o n n e c to r o p t io n s .

P o w e r F le x 5 2 5 A C D r iv e s P o w e rF le x 5 2 5 A C D r iv e s fe a t u re a n in n o v a t iv e , m o d u la r d e s i g n t o s u p p o r t f a s t a n d e a s y i n s t a l l a t i o n a n d c o n f ig u r a t io n . T h is n e x t g e n e r a t io n o f c o m p a c t d r iv e s

o f f e r s e m b e d d e d E t h e r N e t / I P c o m m u n i c a t i o n s , U S B p ro g ram m in g , a n d s ta n d a rd s a fe t y fe a tu re s .

P o w e rF le x 5 2 5 d r iv e s , w h ic h o f fe r a p o w e r ra t in g o f 0 .4 ...2 2 kW (0 .5 ...3 0 H p ) w it h g lo b a l v o lt a g e c la s s e s o f 1 0 0 ...6 0 0 V, p ro v id e a v a r ie t y o f m o to r c o n t ro l a n d fl e x ib le m o u n t in g o p t io n s . P o w e rF le x 5 2 5 A C d r iv e s o p e ra te a t te m p e ra tu re s a s h ig h a s 7 0 °C (1 5 8 °F ), a n d th e y a re id e a l fo r a p p lic a t io n s s u c h a s c o n v e y o rs , fa n s , p u m p s , a n d m ix e rs .

P o w e r F le x 5 2 5 d r iv e s n o w h a v e t h e o p t io n o f p e rm a n e n t m a g n e t m o t o r c o n t r o l t h a t c a n h e l p i m p r o v e e n e rg y e f f ic ie n c y a n d r e d u c e r e la t e d c o s t s . T h e h i g h e r p o w e r d e n s i t y p r o v i d e d b y p e r m a n e n t m a g n e t m o to rs o fte n re su lt s in a m o to r s iz e re d u c t io n w h ile m a in t a in in g t h e s am e o u tp u t to rq u e .

PRODUCT & SOLUTION FOCUS

22 ASIA PACIFIC

N e w E le c t r o n ic O v e r lo a d R e la y H e lp s P r e v e n t M o t o r D a m a g e , D o w n t im e

T h e n e w A lle n -B ra d le y E100 Electronic Motor Overload Relay c a n h e lp in d u s t r ia l c o m p a n ie s b e t t e r p ro t e c t t h e ir m o t o r s a n d a v o id u n p la n n e d d o w n t im e . A s t h e n e x t

g e n e r a t io n o f A lle n -B r a d le y e le c t ro n ic o v e r lo a d r e la y s , i t m o re a c c u ra te ly m e a su re s a m o to r ’s c u r re n t lo a d , m o d e ls it s te m p e ra tu re a n d s h u t s t h e m o to r o f f w h e n it ’s in d a n g e r o f d a m a g e d u e t o o v e rh e a t in g .

O p t io n s a re a v a ila b le to im m e d ia te ly d e te c t jam s a n d g ro u n d fa u lt s , e n a b lin g fa s t e r re s p o n s e s t o t h e s e s p e c if ic c o n d it io n s . A re m o te re s e t o p t io n is a ls o a v a ila b le fo r c u s to m e rs to re m o te ly re s e t t h e o v e r lo a d .

T h e E 1 0 0 o v e r l o a d r e l a y c o m e s i n b a s i c a n d a d v a n c e d c o n f ig u r a t io n s . T h e b a s ic m o d e l h a s t w o u s e r -a d ju s t a b le t r ip -c la s s s e t t in g s o f 1 0 a n d 2 0 . T h e a d v a n c e d m o d e l h a s fo u r t r ip c la s s s e t t in g s : 1 0 , 1 5 , 2 0 a n d 3 0 . A b o v e a s e n s in g ra n g e o f 1 0 0 A ,

t h e a d v a n c e d m o d e l c a n u s e e x t e r n a l c u r r e n t t r a n s f o r m e r c o n fig u ra t io n s to a c h ie v e a m a x im u m ra t in g o f 8 0 0 A .

T h e E 1 0 0 o v e r lo a d r e la y i s p a r t o f t h e R o c k w e l l A u t o m a t io n in te g ra te d m o to r c o n t ro l s y s te m . It c a n m o u n t d ire c t ly to b u lle t in 5 0 0 N EM A c o n ta c to rs a n d 1 0 0 -C IE C c o n ta c to rs u p to 1 0 0 A .

R o c k w e ll A u t o m a t io n H e lp s S e c u r e In d u s t r ia l O p e r a t io n s b y E a r n in g N e w C e r t ifi c a t io n s R o c k w e l l A u t o m a t io n c o n t in u e s t o a d d t o i t s l i s t o f

a c h ie v e m e n ts in in d u s t r ia l c y b e rs e c u r it y to h e lp in d u s t r ia l c o m p a n ie s fo c u s m o re o n t ra n s fo rm in g th e ir b u s in e s s a n d

w o r r y le s s a b o u t p o t e n t ia l c y b e r s e c u r i t y r i s k s . T h e c o m p a n y re c e n t ly re c e iv e d ISA/IEC 62443-2-4 certification, w h ic h d e fin e s s e c u r it y re q u ire m e n ts fo r s e r v ic e p ro v id e rs .

T h e c e r t if ic a t io n s h o w s t h a t t h e security capabilities R o c k w e ll A u t o m a t i o n u s e s w h e n q u o t i n g , d e s i g n i n g , i n t e g r a t i n g a n d m a in t a i n i n g a u t o m a t i o n s y s t e m s m e e t t h e s t a n d a r d ’s re q u ire m e n ts . IS A /IE C 6 2 4 4 3 is th e w o r ld ’s o n ly c o n s e n su s -b a s e d c y b e rs e c u r it y s ta n d a rd fo r in d u s t r ia l c o n t ro l a p p lic a t io n s .

R o c k w e ll A u to m a t io n a ls o re c e iv e d a m a tu r it y -le v e l in c re a s e in t h e IS A / IE C 6 2 4 4 3 -4 -1 c e r t i f ic a t io n i t o b t a in e d la s t y e a r fo r i t s S e c u r it y D e v e lo p m e n t L ife c y c le , s h o w in g t h e c o m p a n y m e e t s t h e s t a n d a rd ’s s e c u r i t y r e q u ire m e n t s in t h e w a y p ro d u c t s a re p ro d u c e d a n d s u p p o r te d . In a d d it io n , t h is s h o w s t h e c o m p a n y h a s m a tu re p ro c e s s e s to h a n d le v u ln e ra b ilit y d is c lo su re s a n d w o rk t ra n sp a re n t ly w ith c u s to m e rs to h e lp m a n a g e th e ir r is k .

T h e n e w c e r t i f i c a t i o n s w e r e i n d e p e n d e n t l y p e r f o r m e d b y T Ü V R h e in la n d a n d a d d t o a g ro w in g lis t o f o n g o in g R o c k w e ll A u t o m a t io n a c h ie v e m e n t s a s t h e c o m p a n y h e lp s c u s t o m e r s s t re n g th e n c y b e rs e c u r it y .

“In d u s t r y n e e d s p a r t n e r s t h a t c a n h e lp t h e m u s e t e c h n o lo g y t o e x p a n d w h a t ’s p o s s ib le in t h e ir o p e ra t io n s w h ile p ro t e c t in g w h a t m a t t e r s m o s t t o t h e m ,” s a id B la k e M o re t , C E O , R o c k w e ll A u t o m a t io n . “W h e n c o m p a n ie s w o r k w i t h u s , t h e y c a n t a k e c o m fo r t k n o w in g w e p ro v id e p ro d u c t s a n d s e r v ic e s b u ilt w it h s e c u r it y in m in d . T h e s e c u r it y re q u ire m e n ts in IS A /IE C 6 2 4 4 3 a re n ’t

a m e re c h e c k lis t fo r u s , th e y ’re e m b e d d e d in o u r e v e r y d a y w o rk .”

E a r l i e r t h i s y e a r , R o c k w e l l A u t o m a t i o n i n t r o d u c e d t h e f i r s t in d u s t r ia l c o n t ro lle r c e r t i f ie d t o IS A / IE C 6 2 4 4 3 -4 -2 , w it h m o re p r o d u c t s t o f o l lo w . R o c k w e l l A u t o m a t io n i s a ls o a f o u n d in g m e m b e r o f t h e IS A G lo b a l C y b e rs e c u r it y A llia n c e , a c o a lit io n o f in d u s t r y , g o v e rn m e n t a g e n c ie s a n d o th e rs w o rk in g to h e lp s e c u re m a n u fa c tu r in g a n d c r it ic a l-in fra s t ru c tu re o p e ra t io n s .

R o c k w e l l A u t o m a t io n i s a l s o w o r k in g t o e x p a n d t h e u s e o f t h e O D VA C IP S e c u r i t y p ro t o c o l, w h ic h h e lp s m a k e s u re o n ly a u th o r iz e d d e v ic e s a re c o n n e c te d in in d u s t r ia l o p e ra t io n s . It a ls o h e lp s p re v e n t t a m p e r in g o r in t e r fe re n c e w it h c o m m u n ic a t io n s b e t w e e n t h o s e d e v i c e s . R o c k w e l l A u t o m a t io n r e le a s e d t h e C o n t ro lL o g ix E th e rN e t/IP c o m m u n ic a t io n m o d u le e a r lie r th is y e a r a n d is p la n n in g t o in t ro d u c e n e w t e c h n o lo g ie s t o e x p a n d C IP S e c u r it y p ro te c t io n to le g a c y a n d n o n -C IP S e c u r it y d e v ic e s in th e c o m in g y e a r.

In a d d it io n , th e u p c o m in g re le a s e o f th e P la n tPA x 5 .0 d is t r ib u te d c o n t ro l s y s te m is e x p e c te d to in c lu d e IS A /IE C 6 2 4 4 3 -3 -3 c e r t ifi e d a rc h it e c t u re s t o h e lp u s e r s d e p lo y a p p ro p r ia t e c o n t ro l s y s t e m s e c u r it y le v e ls .

“L e a d in g in d u s t r ia l c o m p a n ie s h a v e p u t d ig it a l t r a n s fo rm a t io n a t t h e t o p o f t h e i r a g e n d a fo r t h e c o m p e t i t iv e a d v a n t a g e s i t p re s e n ts ,” s a id M a t t L it t le fi e ld , p re s id e n t a n d p r in c ip a l a n a ly s t , L N S R e s e a rc h . “U n fo r tu n a te ly , le g a c y a u to m a t io n a n d c o n t ro l s y s te m s a re n o t in h e re n t ly s e c u re . R o c kw e ll A u to m a t io n h a s a s t ro n g t ra c k re c o rd in d ig it a l t ra n s fo rm a t io n a n d in e m b ra c in g th e p ro c e s s e s , p ro c e d u re s , p ro d u c t s a n d s e r v ic e s th a t s u p p o r t s t ro n g in d u s t r ia l s e c u r it y .”

PRODUCT & SOLUTION FOCUS

M an u fa c tu re rs c a n n o w re a liz e th e d e s ig n a n d p ro d u c t iv it y b e n e f it s o f O n -M a c h in e I/O m o d u le s o n sm a r t m a c h in e s u s e d in h a rsh a p p lic a t io n s .

T h e n e w A lle n -B ra d le y ArmorBlock I/O modules c a n o p e ra te in a w id e ra n g e o f te m p e ra tu re s a n d o ff e r u p to IP 6 9 K p ro te c t io n in a p p lic a t io n s lik e a u t o m o t iv e , m a t e r ia l h a n d lin g , p a c k a g in g a n d w e ld in g .

T h e n e w A rm o rB lo c k I/O o p t io n s c a n b e m o u n te d a n y w h e re o n a m a c h in e fo r s h o r t e r c a b le r u n s a n d lo w e r w ir in g c o s t s . T h e y u s e n i c k e l-p la t e d z in c d i e -c a s t h o u s in g , h a v e Q u i c k C o n n e c t f u n c t io n a l i t y a n d o f fe r d ia g n o s t ic s in a n E t h e rN e t / IP u n iv e r s a l d ig it a l I/O b lo c k t o re d u c e c o m m is s io n in g a n d t ro u b le s h o o t in g t im e s .

T h r e e IO -L in k h u b b lo c k s h e lp r e d u c e d e s ig n c o m p le x i t y b y a llo w in g m o re d e v ic e s t h ro u g h t h e IO -L in k m a s te r. A n d a n M 1 2 L-c o d e d p o w e r c o n n e c t o r o n s e le c t e d b lo c k s s u p p o r t s h ig h e r c u r re n t , a llo w in g m o re b lo c k s to b e d a is y -c h a in e d a n d re su lt in g in lo w e r w ir in g a n d in s ta lla t io n c o s t s .

F o r c o m p a n ie s w ith s e p a ra te I/O b lo c k s fo r d ig ita l in p u t a n d o u tp u t , t h e A rm o rB lo c k I/O m o d u le s a re a n id e a l c h o ic e . T h e y p ro v id e 1 6 -c h a n n e l s e lf-c o n fig u ra b le d ig it a l I/O w ith fl e x ib ilit y to b e u s e d a s th e d ig ita l in p u t o r o u tp u t d e p e n d in g o n th e a p p lic a t io n n e e d s .

ASIA PACIFIC 23

S im p li f y S m a r t M a c h in e s in H a r s h A p p l ic a t io n s w i t h N e w A rm o r B lo c k I /O M o d u le s

Moda is a global leader in producing high performance modular food packaging equipment. Moda integrates the latest technology with hygienic design for the vacuum packaging of meat and dairy products.Moda equipment has been crafted to endure the challenges of demanding environments, increase productivity, and deliver energy, labor and total package cost savings. The rigorously tested line of Moda systems provides improved ergonomics, product-flow and food safety, also.

Moda Packaging System

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