Production Readiness
Improve start-up and changeover performance.
Operational Integrity for Life Sciences
Meet production schedules consistently using industrial software, control systems, data management, and intelligent devices across operations.
Meet production schedules consistently using industrial software, control systems, data management, and intelligent devices across operations.
Today’s Life Sciences companies are being challenged on multiple levels in the face of demands to maintain growth and address margin pressure. This means you must supply products in full on time with shorter production set-up time, reliable equipment, and optimized control strategies to increase uptime. Only a supplier with a diverse product portfolio and global reach, with solutions for large manufacturing and small startups, can help you maximize your operations and expand quickly. With the right control system, intelligent devices, and enterprise industrial software, you can meet your dynamic manufacturing demands.
With an optimized digital strategy, you can move from data silos that have limited integration across functions to an adaptive plant that has full enterprise value chain integration and lays the groundwork for autonomous operations. A digitally mature operation includes fully automated digitized business processes, proactive and predictive analytical analysis, machine learning, and digital twins. A digital facility optimizes production, streamlines the process to meet product quality, efficiently handles exceptions, removes manual documentation for regulations, and increases profitability.
Reactive maintenance based on problems and challenges increases unplanned downtime and compromises schedules. Preventative maintenance based on time schedules can result in unnecessary work and the use of spare parts before they are needed. Leveraging Emerson’s Aspen Mtell® enables reliability and maintenance engineers to monitor the performance of assets, providing real-time visibility into asset health and actionable insights for faster decision-making and more accurate maintenance. And with smart devices capturing data from the field you have the right information, increasing uptimes and improving efficiency so you can continue to meet production performance demands.
When operators are unprepared for infrequently encountered events, unnecessary mistakes may happen, resulting in deviations and product losses. Personnel trained to handle all situations effectively decreases deviations, maintains the production schedule, and optimizes changeover to the next products. Leveraging Emerson’s Digital Twin Solutions reduces the time and effort required to create and deliver comprehensive operator training, decreasing errors that cause off-spec and downtime.
Manual scheduling updates are time-consuming, and errors can be made. Real-time, automated updates to schedules can streamline operations and minimize downtime. In addition, you can predict how automation will behave in the future by visualizing facility constraints, accommodating variability, maximizing production, and understanding any implications of any change in manufacturing. Using DeltaV Real-Time Scheduling, you can collect data across the organization to consolidate, analyze, and ensure accurate scheduling for the entire process.
Frequently Asked Questions About Operational Integrity for Life Sciences
Process automation is the use of software and technologies to automate manufacturing processes and functions. This ensures accurate production and efficient procedures that save costs and improve performance. With the proper process automation solutions, you decrease time-to-market, optimize production, reduce errors and deviations, and increase production efficiency, improving profitability. This can be achieved by using intelligent devices and sensors to sense equipment health, creating control strategies that deliver consistent processes, and implementing data integration to provide a complete picture of manufacturing across various functions to mitigate production delays.
Strengthening worker safety by emphasizing equipment reliability is essential to operating at peak performance. With the right sensors and health monitoring equipment, you can identify problems before they impact process control and worker safety while at the same time minimizing variability and decreasing deviations. A reliability-centered equipment and safety strategy protects assets and operational integrity in terms of both people and machinery.
Provide a hands-on training approach with a simulation of your actual process. Using DeltaV™ Mimic Foundation, training managers introduce simulated scenarios, process upsets, and equipment failures, allowing operators to experience plant events and situations in a realistic training environment. This lays the foundation for personnel effectiveness.
