Improve Operator Performance to Drive Consistent Production

Decrease production delays with the correct response to upset situations, lowering variability in recipe execution and ensuring accurate recording.

Cell culture laboratory of a biotechnology facility with operator in scrubs reviewing process unit instructions

Repligen Automates Manual Documentation Saving 10 Hours a Week

Repligen produces extremely high value products in small batches, requiring critical documentation. When product is produced, 200 procedural and process documents are required with highly detailed information, taxing plant personnel. Automating documentation increased internal procedural compliance, decreased issuance time per batch record and ensured on-schedule review.

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Solution in Action: Reduce Unscheduled Downtime Due to Operator Work Practices

Real-Time Measurements and Accessible Data Allow Appropriate Timely Actions

Pharmaceutical industry and drug manufacturing worker in sterile facility reviewing data about a process

Lack of real-time measurements or actionable data, difficulties in accessing and viewing key performance metrics, and silos of information result in operators making poor decisions or failing to take appropriate timely actions when needed. With the right instruments collecting data, and the software to integrate the data from various sources in the plant, operators can see challenges before they become a problem and understand actions needed for optimal production.

Mimic Field 3D provides immersive training experience powered by virtual reality technology

DeltaV™ Mimic Field 3D

Reduce critical path timelines for product deployments and changeovers with 3D visuals, allowing operations to become spatially aware of production.

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Quality Review Manager

Identify and resolve exceptions in near real-time, reducing time spent in batch review, and improving batches that can auto-close/release.

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Digital Twin Solutions

Reduce time and effort required to create and deliver comprehensive operator training, decreasing operator errors which cause off-spec batches and downtime.

AspenTech Inmation™

Centralized data management system that allows for the ingestion, processing, augmentation and storage of diverse data, empowering your team from the plant floor to the executive suite.

AVENTICS™ 580 CHARM Node + 500 Valve Manifold

Provides a cost-effective installation and allows for visibility into steam traps by accurately communicating acoustic level and temperature data as well as device data and event status.

Plantweb™ Steam Trap Insight Application

Rosemount 708 Wireless Acoustic Transmitter with Plantweb Insight Steam Trap Application

Provides a cost-effective installation and allows for visibility into steam traps by accurately communicating acoustic level and temperature data as well as device data and event status.

AMS Device Manager

Plant-wide visibility into the data, health, and key analytics of intelligent field devices.

AMS Trex Device Communicator

Accurately configure and troubleshoot smart devices in clean, sterile rooms without pulling devices from the field using wireless technology.

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Effective Training Improves Responses to Abnormal Situations and Limits Deviations

Pharmaceutical manufacturing operator in clean environment adjusting the process unit specifications

Insufficient or ineffective overall training, such as limited training environment exposure to appropriate responses for abnormal situations, causes deviations and inconsistent production performance. Leveraging simulation software to train workers with an exact replica of the plant allows operators to practice scenarios and learn the best way to respond, minimizing errors and inappropriate actions. This helps employees to improve their productivity as they gain insights into the underlying mechanisms and interactions that affect production.

Digital Twin Solutions

Reduce time and effort required to create and deliver comprehensive operator training, decreasing operator errors which cause off-spec batches and downtime.

Quality Review Manager

Identify and resolve exceptions in near real-time, reducing time spent in batch review, and improving batches that can auto-close/release.

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DeltaV Electronic Batch Records Management

Electronic records improve compliance, reduce errors, streamline the ability to trace actions, and provide simultaneous generation of documentation.

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DeltaV™ Mimic Foundation

Upskill workers to fully utilize today’s digital plant technologies with an exact replica of the DeltaV production system for training and tech transfer.

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Frequently Asked Questions About Upskilling Personnel Effectiveness

How can I train my operators effectively?

Training your life sciences operators effectively is a key factor for ensuring product quality. By leveraging simulation software with a proven methodology, operators can practice specific situations to learn how to handle many different operating scenarios before they happen. With Emerson’s DeltaV™ Mimic Foundation, accurate real-time simulation of how the plant behaves with true-to-plant graphics and controls, operators can learn how to manage various situations to minimize errors and deviations.

What is the best way to resolve exceptions/deviations?

With the use of Quality Review Management, many exceptions can be automatically generated based on the exception type. With near- real-time identification of exceptions, the capture of the data and situational details regarding any exception or deviation can be accurately captured soon after the event. The ability to see the exceptions quickly helps operators, supervisors, and quality personnel to quickly find and review the data to determine if the exceptions affect product quality.

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Explore More Solutions

Modern pharmaceutical manufacturer with operators inside standard clean sterile room

Production Readiness

Improve start-up and changeover performance using industrial software, control systems, and intelligent devices.

Modern pharmaceutical manufacturer with operator in a clean sterile room

Facility/Line Efficiency

Optimize facility line management with control software and instrumentation to improve visibility, testing, and consistency.

Production operator in sterile manufacturing facility troubleshooting equipment

Equipment Reliability

Improve material production and limit deviations with intelligent devices and a robust control strategy.

Pipeline Acceleration

Ensure new product development releases drugs to market faster.

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