Challenges:

• Apply DMAIC (Define, Measure, Analyze, Improve, Control) principals.

• Accuracy and timeliness of manufacturing data into a continuous improvement program.

• Engage, empower, and inspire to become more involved in the performance improvement process.

• Maintaining the highest product quality while significantly reducing production costs.

• Wide variability in needed production time for products.

• Schedule compliance.

Goals:

• Automate OEE data collection and reporting in formulation and packaging areas.

• Identify root causes for equipment downtime.

• Promote operator involvement in the improvement process.

• Improve availability of a water utility system as a pilot to quantify the benefits that could be achieved by having accurate information on system performance, Ozone cycle times, and alarms.

Solution:

TrakSYS Solution Approach

TrakSYS™ solution not only had to provide real-time information with trusted accuracy, it also had to deliver the needed functionality to facilitate the AstraZeneca journey.

TrakSYS™ Solutions Architecture

The full site implementation included:

• Formulation areas of tablet compression and coating machines.

• Packaging lines inclusive of blister, bottle, vial, and hand pack operations.

• Utilities - USP Purified Water System.

• In accordance with site IT standards, TrakSYS™ was deployed as a central application server with OPC connection over Ethernet LAN to the SCADA System and SENSORTrak™ data collectors.

• SENSORTrak™ high-speed data collectors networked via Ethernet LAN, capture and draw production data from various production systems.

• 25 EVENTTrak™ operator interface nodes were placed throughout the facility to enable interaction with the systems (e.g., view information, reports, enter observations, categorize events, etc.).

• 70 concurrent web users across operations and production.

• Integration with SAP/MII for KPI visualization on LCDs on the production floor.

• Plant-wide user workstations to view production and performance information via standard browser technology.