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#PIWorld ©2020 OSIsoft, LLC#PIWorld ©2020 OSIsoft, LLC
Advances in Data Analytics for Continuous Manufacturing
Laura Wareham, MerckEmily Johnston, Seeq
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#PIWorld ©2020 OSIsoft, LLC
Advances in Data Analytics for CM
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Laura Wareham• Senior Scientist at Merck & Co., Inc.• [email protected]
Emily Johnston• Analytics Engineer at Seeq• [email protected]
#PIWorld ©2020 OSIsoft, LLC
Agenda• Welcome and Introductions• Challenge – Maximize Value from Data• Solution – Process Characterization with PI & Seeq
• Use Case 1: Loss-in-Weight Feeder Dashboards• Use Case 2: Film Coating Parameter Analysis
• Results – Process Optimization & Shared Insights• Future Opportunities
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#PIWorld ©2020 OSIsoft, LLC
About Our Company
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#PIWorld ©2020 OSIsoft, LLC
About Our Company
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AUTOMATION/CONTROL SYSTEMS NEW SENSOR TECHNOLOGY REMOTE AND MOBILE ASSETS
EnterpriseInfrastructure
Advanced analytics: application of big data, machine learning, and other innovations to derive insights and improve outcomes
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PI VisionPI NotificationsEvent FramesPI AFPI Data Archive
Advanced Analytics for OSIsoft PI System
OSIsoft Cloud Services
Industrial A Service Provider
MQTT Service Provider
#PIWorld ©2020 OSIsoft, LLC
Continuous Manufacturing“Material is fed through an
assembly line of fully integrated components. This
method saves time, reduces the likelihood for
human error, and can respond more nimbly to
market changes.”Sau (Larry) Lee, Ph.D.
Chair of the Emerging Technology Team Office of Pharmaceutical Quality, CDER
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https://www.thomasnet.com/articles/machinery-tools-supplies/overview-of-food-processing-equipment/
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#PIWorld ©2020 OSIsoft, LLC
Goal: Maximize Value from Data
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Process Data
Contextual Data
BusinessSystems
Manufacturing Systems
Subject MatterExperts
Data Access and Manipulation
Algorithms andTools
Process Visualization
Data Analytics
Operationalize normal production behavior to proactively identify trends or process deviations
#PIWorld ©2020 OSIsoft, LLC
Loss-in-Weight Feeders
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https://www.youtube.com/watch?v=BqDdkMMQR9k
#PIWorld ©2020 OSIsoft, LLC
Feeder Challenge
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2 3 4
6 7 8 Modes of OperationProcess TrendsPerformance Statistics
#PIWorld ©2020 OSIsoft, LLC
DEMOFeeder Dashboard
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#PIWorld ©2020 OSIsoft, LLC
Feeder Dashboards
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#PIWorld ©2020 OSIsoft, LLC
Film Coating
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https://www.youtube.com/watch?v=FXRjt1RZ3CQ
#PIWorld ©2020 OSIsoft, LLC
Coater Challenge
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Identify Operating Mode Create KPIs
#PIWorld ©2020 OSIsoft, LLC
DEMOCoater Dashboard
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#PIWorld ©2020 OSIsoft, LLC
Coater Analyses
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#PIWorld ©2020 OSIsoft, LLC
Results: Analytics Strategy
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LeverageHistorical Data
Apply Advanced Analytics
Enable Personnel
Optimize Business
#PIWorld ©2020 OSIsoft, LLC
Looking Ahead
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Expand AnalysesStatistical Process ControlCondition Based Maintenance
Integrate with PI System Features
Event Frames
Asset Framework
“With enough information and quality content, these technologies can transform data into knowledge that supports critical activities,
including process optimization, continuous improvement, operational excellence, and even real-time release.”
Pharmaceutical Engineering, Sep/Oct 2018
#PIWorld ©2020 OSIsoft, LLC
CHALLENGES SOLUTION BENEFITS
Accessing large CM data sets for rapid process analysis
Sharing analysis and insights across the broader team
Applying learnings and analysis proactively to future lots
Utilize PI DataLink, PI ProcessBook, and Seeq to characterize the process
Calculate statistics to understand normal process variability
Generate reports for process visualization and performance analysis
Greater insight into real-time process performance
Visual feedback during operation using monitoring dashboards
Rapid analysis summarized in performance reports for broader team distribution
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“Modern data analysis tools like SEEQ enable new ways for SMEs to interact with their data including rapid insights into process performance.”
Justin Moser, Merck, Advanced Manufacturing Technology
#PIWorld ©2020 OSIsoft, LLC
Advances in Data Analytics for CM
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Laura Wareham• Senior Scientist at Merck & Co., Inc.• [email protected]
Emily Johnston• Analytics Engineer at Seeq• [email protected]
#PIWorld ©2020 OSIsoft, LLC 24
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