Why take a preventive approach?

B&R'southward X20 module for status monitoring is a snap to integrate into an overall automation solution – no expertise in vibration mechanics is required

The pharmaceutical manufacture is characterized by stiff regulations and is obliged to evangelize a product with a divers quality to the consumer. The process and manufacturing equipment information technology uses plays a major role in influencing production quality and business efficiency. A breakdown could hamper drug quality and hence an organization'due south competitiveness.

Machine builders are deploying available technologies such equally condition monitoring, remote monitoring and diagnostics for ensuring high machine availability with safety and security in pharmaceutical processing and packaging operations. In improver, these technologies ensure the maintenance of optimal production quality, lower automobile downtime, amend equipment reliability and increase overall efficiency.

Importance of status monitoring

'If it'due south not broken, don't gear up it' still applies to many industries. Yet, the pharmaceutical industry cannot follow this technique as downtimes impact both product quality and the compliance with pharmaceutical processes. The success of an organization heavily depends on production performance in terms of increased equipment and institute availability. This is feasible only past optimizing and improving maintenance processes.

Condition Monitoring meets the requirement of modernistic and competitive manufacture. Information technology helps to maximize the effectiveness of equipment, a system or an entire found. Properly planned and executed condition monitoring tin can aid to minimize downtime, maximizing equipment efficiency and reliability, reducing operating price, improving equipment and operator safety, saving time amidst others.

The APROL process control system from B&R and the individual APROL ConMon solution is extremely constructive at further increasing pharma production efficiency

Condition monitoring assures machine and operator condom past highlighting possible issues fifty-fifty before they occur and effect in downtime. In pharmaceutical manufacturing, a number of factors such as temperature rising, unknown vibrations, are responsible for wear and tear of machines. In addition, these machines are designed to perform continuous production, where stoppage, malfunctioning or breakup of fifty-fifty a single machine can cease the entire plant, resulting in enormous material, production and quality loss.

Past using status monitoring, manufacturers tin can monitor real-time status of a machine and plant, operational conditions, together with historical information for comparison and analytics. Successful condition monitoring coupled with secure advice enables machine builders to monitor their avails 24/seven. Based on status data analytics, maintenance teams can predict possible failures and plan for necessary maintenance schedules without hampering production.

Risk assessment while implementing condition monitoring

Machines, devices, sensors, and the workforce needs to connect and communicate seamlessly with each other. Ane of the biggest obstacles in implementing data-driven monitoring of operational conditions or energy consumption is making the information flow from machines to ERP systems with a high level of security. It is important to protect machine data, production process data, drug formulation information, which are the intellectual holding of the pharmaceutical company. Breach of such data by whatsoever means will atomic number 82 to financial damage; touch on a company's reputation and overall stability. Given all of these factors, the It section places a priority on data security, confidentiality and integrity to a higher place all.

Keeping track of your assets

Production heads in pharma production are all too familiar with the dilemma – How to meliorate production quality and increase system availability, while at the same fourth dimension cutting back on maintenance costs? B&R's answer to this dilemma is condition monitoring every bit a pre-installed, pre-configured bundle that makes implementing predictive maintenance straightforward. B&R's X20 module offers real-time status checks of machines, critical manufacturing assets, and utilities. It offers real-fourth dimension insights of the wellness and efficiency of assets.

With these modules, B&R has introduced onboard intelligence for vibration analysis that can brand monitoring an integrated and standard feature in every machine. By maximizing machine availability while minimizing the fourth dimension and coin spent on maintenance, the X20 module allows meaning reductions to the total toll of ownership of machines and systems. The condition parameters generated by this module not merely provide operators with the information they demand to optimize maintenance intervals simply also are available for use directly every bit input in the automation software. An IEPE interface for querying acceleration sensors samples signals and processes them internally to generate more than lxx status parameters, which are then transferred direct to the CPU via Powerlink or any other standard field-bus arrangement.

In order to improve overall plant efficiency including auxiliary buildings, energy, and utilities, B&R also offers condition monitoring solution packages from APROL that extend from the I/O level up to the process control system for the entire plant. B&R's APROL process command system makes information technology possible to unite found systems centrally into a complete system using any conceivable hierarchy. With a broad spectrum of functions – including integrated organisation simulation using MATLAB/Simulink – all levels of automation can exist combined into a homogeneous system.

With direct integration of external systems and signal sources, APROL allows an all-encompassing approach that ensures reliable and efficient functioning of the system over its entire service life. Continuous status monitoring increases the quality of products and the availability of machines and plants, while at the same fourth dimension reducing maintenance costs. B&R's APROL ConMon solution package provides vibration monitoring and assay based on key condition parameters calculated from acquired measurement data. The condition monitoring solutions fit perfectly for a machine as well as factory automation.

Shyam Padwal, Lead – Pharma Industry Vertical, B&R Industrial Automation

Safety and security for product lines

Owing to proprietary protocols, seamless car-to-automobile communication and machine-to-IT communication inside a facility was uncommon and the topic of cybersecurity was non of great business organization. However, things are changing with the increasing use of new applied science opening upwardly potential targets for hackers. B&R has introduced the SiteManager for balancing the needs of production and IT with enhanced security. The device has an integrated firewall and takes intendance of cybersecurity. Having the SiteManager between the controller and the net/cloud ensures that whatever data transferred between the machine and applications outside of the company network is protected confronting unauthorized access. To transfer information to the cloud, the controller connects with the SiteManager via OPC UA and is capable of transmitting this to the upper layers via MQTT.
OPC Unified Architecture (OPC UA) is a vendor-independent communication protocol for industrial automation applications. OPC UA bridges the gap betwixt the IP-based globe of IT and the production floor. Information technology is based on the customer-server principle and allows seamless communication from the individual sensors and actuators upward to the ERP system or the cloud. The protocol is platform-contained and features congenital-in condom mechanisms. Since OPC UA is flexible and completely contained, information technology is regarded as the ideal communication protocol for the implementation of Manufacture four.0. B&R relies on open source communication such as OPC UA and is an active fellow member of the OPC Foundation participating in various working groups.

"Pharmaceutical automobile builders and facilities are swiftly recognizing the vast benefits offered by these solutions. They are increasingly turning to make their machines and facilities efficient with lower downtimes. Condition monitoring together with information logging enables them in their attempt to be competitive," explains B&R'due south Lead – pharma manufacture vertical, Shyam Padwal.

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