Leading automation applications and platforms continue to transform processes and operational performance in the life sciences sector. They offer an extensive range of features that continue to improve and evolve. That said, even the best automation platforms and applications have limits. They are designed and developed for specific purposes, and, in many cases, they perform very well. However, life science manufacturing facilities require wider capabilities than are often available within single platforms or applications.
This particularly applies when developing a new line or upgrading an existing line, where multiple machines, platforms, and applications are involved, and compliance considerations are as important as engineering and operational factors. In these situations, customized solutions are needed that facilitate the project’s operational, engineering, and compliance requirements.
The Solution
The solution that is the subject of this case study was developed for a multinational company in the life sciences sector. As part of the company’s growth and continuous improvement, new production lines were installed. Improvements were also made to existing lines. Part of the installation and testing process involved comparing automation software project files on several different platforms:
- Allen Bradley PLCs
- Siemens APT PLC (including APT address reporting)
- Cognex
- Generic files (e.g. robot files)
- Generic folders (e.g. robot files)
- Factory Talk View (currently in development at the time of writing)
- Wonderware Intouch (currently in development at the time of writing)
Some of the programs featured a compare tool but using those tools was challenging and time-consuming. The standard compare tools were also generic so didn’t meet the specific needs required by the customer.
In particular, there was no way to produce a validated history of changes using the standard compare tools, which is a compliance requirement. As a result, remaining compliant when using the out-of-the-box compare tools would have involved engineers taking screenshots of the compare tools output and then manually typing the reason for the change. This created significant scope for human error as well as being time-consuming.
The process for applications without a built-in compare tool was even more laborious.
Our client asked us to create a custom compare tool that would compare all the required automation programs using a validated approach.
What We Did
Our team developed a compare solution that met the client’s requirements as well as delivering additional benefits. A key component of the project was to ensure the solution worked with the required software project files. In some cases, different platform firmware versions were used onsite, so the solution had to be tailored accordingly.
The solution compared the automation software project files as required, automatically producing time-stamped history reports without any human intervention in the process. The solution itself was also validated by our team.
The Results
The main initial advantages for the customer included:
- Validated compare approach – the solution enabled a validated compare approach with the compare tool producing the required compliance documentation, including history reports and code review reports.
- Automated the compare process – the solution also streamlined the process of comparing the automation software project files, significantly reducing the engineering hours needed to complete these tasks.
- Reduction in human error – the solution captures all changes within the software project file. This highlights the change to the developer and reviewer of the project file and ensures no unintended changes are made.
The above benefits reduced the time required for SAT (site acceptance testing) so there was less downtime on the line.
This solution has enabled the customer to implement reduced testing strategies for repeat installations. Existing lines were also improved. Following the implementation and validation of the first software program, we streamlined testing and validation processes even further by using the compare solution to check that repeat implementations were the same as the first.
This further reduced installation time, testing time, and the engineering hours required on repeat installations.
In summary, the main benefits of the customized compare solution include:
- Compare automation software project files using a validated approach.
- Validate the code on the second manufacturing line by comparing it to the first using the compare tool.
- Reduced risk of human error by automating data recording and the production of history reports and code reviews.
- 75% reduction in required automation engineering hours for accurate history generation and highlighting all code changes.
- Reduced SAT execution time.
- Reduction in overall line downtime.
- Improved compliance
“Comparing the automation software project files was an essential part of installing and commissioning the new production lines at this life sciences manufacturing facility. Doing it manually would have needed significant automation engineering resources to complete time-consuming and repetitive tasks. Even then, there was no guarantee the histories would be correct as the entire process was open to human error.
“The solution we developed automated the software project file compare process while also ensuring the process was fully compliant. We were then able to utilise this validated compare approach on subsequent lines to speed up installation and testing times even further.
“Investing in custom software solutions can deliver significant ROI for manufacturers in the life sciences industry. In this case, those returns were delivered through a reduction in automation engineering hours, improved compliance, reduced compliance risks, and improved quality.”
Tom Nolan, SL Controls Program Manager