Authoring Comprehensive Recipes This white paper discusses life cycle benefits of implementing a system that delivers recipe authoring tools that creates a single S88 recipe and downloads the recipe to the MES and DCS system, making it transparent to the user that the manufacturing automation is executed between two different systems.

Authoring Comprehensive Recipes Introduction The life sciences industry is implementing Manufacturing Execution Systems (MES) as a strategy to improve overall manufacturing performance. MES are information technology (IT) solutions that support the primary production processes in a production plant. These applications close the gap between ERP systems and production equipment control, distributed control systems (DCS), programmable logic controllers (PLC), and/or supervisory control and data acquisition (SCADA) applications. MES applications have become essential to support real-time production...

Authoring Comprehensive Recipes S88 Recipe Includes Both Manual and Automated Workflow All life science, plant floor manufacturing requires both processing steps that are manually performed by operators and automated steps that are performed by a batch control system. Manual processing steps include material charges, filter changes, verifying equipment status, etc. Automated processing steps are involved when the processing can be performed by reading instruments and sequencing values, such as heating phases, agitation, and material transfers. When developing the S88 procedural model for plant...

Authoring Comprehensive Recipes Verify Media Preps Equipment Change Filter Material Charge Pressure Check Figure 2: DCS and MES recipes Using the scenario detailed in Figure 2, many considerations need to be made, including: How does Pressure Check know that is has to execute after Change Filter? How does CIP Media Vessel know that completion of Verify Media Prep Equipment and Change Filter are required before it can run? How does Material Charge know that WFI Charge needs to be completed before it can run? How does Mixing know that Material Charge needs to be completed before it can run?

Authoring Comprehensive Recipes How does Transfer know that Sampling needs to be complete before it can run? Combining MES and DCS Recipes with an Engineered Solution The MES implementation shown in Figure 2 is referred to as “paper on glass.” Choosing to implement systems based on this design results in many right-first-time manufacturing benefits being lost. In order to enable the correct sequencing of steps between the MES and DCS systems, effort must be expended to engineer an interface between the two systems to: Initiate sequencing from one system to the other Define coordination and synchronization...

Authoring Comprehensive Recipes In order to achieve custom engineered integration, you will need to: Define a technical environment in which the interfacing can be performed. Will a software program be written? Will soft phases be used? Can this be done using “interface control modules”? An overall approach needs to be designed. Identify an automation and/or IT specialist to knit the two recipes together. Develop a testing strategy for the interface (GAMP Level 4). Develop a validation plan for the interface. Support the interface on an ongoing basis. The cost to develop this custom integration...

Authoring Comprehensive Recipes Product Integrated Recipe Management The best approach toward an integrated MES/DCS solution is a single recipe using a recipe authoring tool that spans the MES and DCS applications, making it unnecessary to develop custom software. Emerson's Syncade Recipe Authoring enables recipes to be written by process and manufacturing personnel and executed on both systems to substantially lower the total life cycle cost. Compliance Suite - Recipe Authoring - MyLibrary - [Diagram - UPPDCFBLENDING] File View Help Master Recipes _ - Automation Steps ** : Diagram - UP_PDCF_BLENDING...

Authoring Comprehensive Recipes White Paper January 2016 ©2016, Emerson Process Management. All rights reserved. Emerson Process Management Reliability Solutions 12001 Technology Drive Eden Prairie, MN 55344 USA T 1(952) 828-3633 F 1(952) 828-3006 www.emersonprocess.com/syncade The Emerson logo is a trademark and service mark of Emerson Electric Co. The Syncade is mark of one of the Emerson Process Management family of companies. All other marks are the property of their respective owners. The contents of this publication are presented for informational purposes only, and while every effort has...