Optimized facility line management provides visibility, lowered variability and improved off-line testing
A biotech facility was having issues from the inability to get a repeatable level measurement on their fermentation vessel. In addition, response time was slow and suboptimal for level control. Adding Emerson’s Rosemount™ 3051S Pressure Transmitter improved the accuracy of measurement from an error rate of 3-5% to less than .05%.
Inability to measure and respond to critical quality attributes in real time, less than optimal equipment performance, and constrained critical resources contribute to lower product yields and reduced facility throughput. By using digital analytics software, you can optimize yield, energy and throughput while ensuring product quality. Leveraging data across various systems allows you to gain more visibility into the process resulting in significant production improvements.
Planification en temps réel DeltaV™
Modéliser n’importe quelle installation ou opération ou n’importe quel procédé pour créer une programmation en temps réel toujours réalisable, détecter les goulots d’étranglement et prévoir la maintenance.
Systèmes et logiciels DeltaV destinés à Life Sciences
Grâce aux éléments constitutifs de l’automatisation, la technologie DeltaV facilite le transfert de technologie du laboratoire à la fabrication et à la vente commerciale.
Système de transmetteur de pression Rosemount™ 3051S avec séparateurs électroniques (ERS)™
Avec son architecture numérique flexible, cet appareil réduit les intervalles de maintenance, accroît le débit et garantit une réactivité supérieure par rapport aux systèmes conventionnels.
Technologie spectrale analytique des procédés DeltaV™
L’analyse multivariée en temps réel permet d’automatiser la fabrication et d’améliorer la qualité et la fiabilité des produits.
DeltaV Predict and PredictPro
Obtain greater throughput, reduced variability, and increased safety for your model predictive control strategies.
Movicon Pro.Lean©
Improve productivity, reduce waste, and increase profits with lean manufacturing and plant intelligence software.
AMS Device Manager
Visibilité à l’échelle de l’usine sur les données, l’état et les analyses clés des appareils de terrain intelligents.
AMS Trex Device Communicator
Accurately configure and troubleshoot smart devices in clean, sterile rooms without pulling devices from the field using wireless technology.
Inherent variability in raw materials, equipment, and processes can lead to higher material consumption costs and inefficient production. In-line monitoring and control of critical processes in real-time helps ensure product consistency, reduces the risk of production upsets, and ensures accurate processing (e.g. material mixing, drying, optimal cell growth conditions, etc.). With access to real-time process, quality, and schedule data, you can optimize production.
Planification en temps réel DeltaV™
Modéliser n’importe quelle installation ou opération ou n’importe quel procédé pour créer une programmation en temps réel toujours réalisable, détecter les goulots d’étranglement et prévoir la maintenance.
Pesage et distribution / Gestion des matériaux syncade
Ensures material management can be tied into electronic batch records to provide real-time verification during production and generates an accurate material genealogy at each stage of production.
Technologie spectrale analytique des procédés DeltaV™
L’analyse multivariée en temps réel permet d’automatiser la fabrication et d’améliorer la qualité et la fiabilité des produits.
DeltaV Predict and PredictPro
Obtain greater throughput, reduced variability, and increased safety for your model predictive control strategies.
Aspen ProMV®
Get early and accurate warnings for process health, providing insights to prevent off-spec production, maintain efficiency and rapidly optimize operations.
Aspen Process Pulse™
Receive early and accurate warnings of product health issues to optimize and improve quality and support PAT in compliance with regulatory requirements.
Energy inefficiencies caused by inconsistent equipment operations, cleaning constraints, CIP issues, and leaking steam traps contribute to unnecessary energy usage, avoidable utility consumption and lost production. Monitoring temperature, pressure or flow rate of equipment will ensure optimal processes and result in reduced energy usage. In addition, leveraging advanced modeling and planning software optimizes operations and equipment, ensuring consistent product quality while using the least amount of energy.
Movicon Pro.Energy©
Achieve consumption goals with an open software solution that has complete connectivity, simplified monitoring, and robust data analysis capabilities.
AspenTech Inmation™
Système centralisé de gestion des données qui permet l’ingestion, le traitement, l’enrichissement et le stockage de données variées, et qui renforce aussi bien les capacités de votre équipe sur site que celles des dirigeants.
Sonde de conductivité Rosemount™ 403
Assurez une réponse rapide aux changements de conductivité entre les cycles de rinçage et de nettoyage en place (NEP) pour minimiser les coûts et maximiser l’efficacité des procédés.
Aspen Mtell®
Profitez d’une alerte anticipée et précise sur le moment de survenue d’une défaillance d’équipement, la manière dont elle se produira et la façon d’y remédier.
Frequently Asked Questions About Facility/Line Efficiency Optimization
Using software, such as DeltaV Spectral Process Analytic Technology (PAT), the critical quality attribute model can be run directly in the control system for real-time prediction and control, eliminating the need to take a sample off-line. For example, blending samples are critical to ensuring materials are mixed properly to minimize deviation and wasted materials. With the right software, you take a sample and adjust in real-time, greatly increasing production efficiency.
It is recommended to focus on optimizing materials, equipment, and people. This can involve leveraging software to predict demand and ensure the correct amount of materials are on hand. In addition, predictive maintenance should be in place to plan and schedule downtime so unexpected equipment failures don’t create deviations or bottlenecks. Dynamic real time updates to schedules need to be in place to accommodate the typical fluctuations encountered in production. By using the data and the model from a process, the bottlenecks can be understood. Additionally, “what if” scenarios can be run to determine how to alleviate the bottleneck and determine what would be the next bottleneck in production. Also, consistent operations are critical, so training personnel to handle unexpected issues in real-time results in smooth operations, with many challenges being prevented. A solution like AspenTech ProMV™ analyzes interrelated process data to identify production capacity degradation and determine potential issues before production is negatively impacted.
Balancing the supply and demand of materials, products, and resources is critical to staying on top of production in real time and understanding asset health. This involves having the right sensors, data analytics and predictive maintenance to monitor asset conditions, identify potential failures, and prevent breakdowns. In addition, taking an enterprise point of view with Emerson's Aspen Supply Chain Planner helps you holistically optimize your global supply chain by building optimal procurement, production, distribution, and inventory plans that meet demand and business revenue goals.
