- Situation: A global leading pharmaceutical manufacturer's two-storey, single-dry-product manufacturing facility runs a production process train consisting of various types of equipment and associated computerized systems, and a variety of support utilities. The production process train is split between two floors. Equipment involved in the production process includes tumble bins, drum containers, bin lift/tumblers, continuous dry mills, tablet presses, tablet dedusters, checkmasters, coating pans, purified water tanks, and perialistic pumps. A Multiple Washer System that consists of five wash units is used to wash/sanitize the equipment in the facility.
- Issues: Regulatory compliance upgrading; security upgrading; refinement of existing reporting and recipe management functionality.
- Requirement: Upgraded automation controls to meet cGMP compliance, provide enhanced security, and expand reporting/recipe management capabilities.
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- Brock Solutions' Role: Full-scale automation engineering (reviewing legacy design documentation; creating a new design draft (including system overview and architecture); converting existing PLCs to a new platform; upgrading HMIs to a newer version; developing a system acceptance test plan; installation); and Commissioning/Qualification/Computer System Validation (CSV).
- Technology: Allen-Bradley ControlLogix programmed in RSLogix 5000, Wonderware InTouch Human Machine Interface (HMI) software, Wonderware InTouch DAServer for network access and MS SQL Server Express, Microsoft Windows XP Professional SP2, Microsoft Excel, Crystal Reports, Ethernet.
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