Samsung Biologics (Pharmaceutical, South Korea)

Samsung Builds for Flexibility and Quality​​​​​​​
Large pharmaceutical companies face manufacturing challenges due to the difficulty in scaling production to adapt to changes in product demand. Understanding those challenges, Samsung Biologics designed a facility that would provide their contract manufacturing customers flexible, reliable, one-stop services for process development, quality control, and production manufacturing at reduced price, while maintaining high quality and regulatory compliance.
Because Samsung needed to take advantage of market conditions, the project schedule from system design to startup was very tight. As they considered automation partners, Samsung valued Emerson’s global project references, execution organization, and capability in Korea, Asia Pacific, and globally. Samsung recognized the opportunity to benefit from the DeltaV™ distributed control system (DCS) and flexible DeltaV technology such as CHARMs.

Solution in the Field and in the I/O
Emerson and Samsung saved project time and costs by implementing strategic technologies. In fact, by choosing DeltaV Electronic Marshalling with CHARMs technology, and configure-toorder I/O enclosures, the team reduced the project schedule and the cost consequences resulting from late I/O changes at the site. 

• Installation of field-mounted I/O enclosures: Wherever possible, Samsung standardized on a specific I/O field enclosure design to reduce engineering and installation work. Additional savings came from reduced wiring required to connect junction boxes to devices.
• Reduction in loop check and commissioning: Only one person (rather than two) per instrument was needed to perform this task, thus saving schedule time and labor cost.
• Reduction in late changes to wiring: For any late changes in I/O design, CHARMs simplified reassigning I/O, Electronic Marshalling meant less rewiring and conduit, and field enclosures reduced the cost to run changes to the control system.
• Reduced FAT time: Samsung successfully used a phased approach for the FAT. Hardware and software testing was performed separately as the engineering personnel were available, then the tested elements were delivered as the site became available.

Don’t Meet the Budget, Beat it
Overall, the CAPEX savings was approximately $3M with project schedule reduction totaling about 7800 hours and field installation savings of 6000 hours.
Samsung realized that not only could they meet time and cost goals for the facility start up, but future process operation and changes would meet fluctuating customer demands. Electronic Marshalling and CHARMs have proven to streamline changes and the junction boxes in the field mean lower continued wiring costs.