Improve Production Efficiency and Remove Bottlenecks
Biotech Facility Increases Throughput on Fermentation Vessel
A biotech facility was having issues from the inability to get a repeatable level measurement on their fermentation vessel. In addition, response time was slow and suboptimal for level control. Adding Emerson’s Rosemount™ 3051S Pressure Transmitter improved the accuracy of measurement from an error rate of 3-5% to less than .05%.
The Right Control and Instrumentation Improves Throughput
Measure and Respond to Critical Quality Attributes in Real-Time
Inability to measure and respond to critical quality attributes in real time, less than optimal equipment performance, and constrained critical resources contribute to lower product yields and reduced facility throughput. By using digital analytics software, you can optimize yield, energy and throughput while ensuring product quality. Leveraging data across various systems allows you to gain more visibility into the process resulting in significant production improvements.
DeltaV™ Real-Time Scheduling
Model any facility, operation, or process to create always-feasible real-time scheduling, to detect bottlenecks and to predict maintenance.
DeltaV Systems and Software for Life Sciences
DeltaV technology facilitates easy tech transfer from lab to manufacturing and commercial sales with automation building blocks.
Rosemount™ 3051S Electronic Remote Sensor (ERS)™ System
Engineered with a flexible, digital architecture this device reduces maintenance time, increases throughput and offers faster response time than traditional systems.
Accommodate Materials and Equipment Variability to Minimize Disruptions
Inherent variability in raw materials, equipment, and processes can lead to higher material consumption costs and inefficient production. In-line monitoring and control of critical processes in real-time helps ensure product consistency, reduces the risk of production upsets, and ensures accurate processing (e.g. material mixing, drying, optimal cell growth conditions, etc.). With access to real-time process, quality, and schedule data, you can optimize production.
DeltaV™ Real-Time Scheduling
Model any facility, operation, or process to create always-feasible real-time scheduling, to detect bottlenecks and to predict maintenance.
DeltaV MES Materials Management
Ensures material management can be tied into electronic batch records to provide real-time verification during production and generates an accurate material genealogy at each stage of production.
DeltaV™ Spectral Process Analytics Technology
Real-time multivariate analysis unlocks automated manufacturing, improving product quality, and reliability.
Increase Energy Efficiency and Avoid Utility Consumption to Lower Production Costs
Energy inefficiencies caused by inconsistent equipment operations, cleaning constraints, CIP issues, and leaking steam traps contribute to unnecessary energy usage, avoidable utility consumption and lost production. Monitoring temperature, pressure or flow rate of equipment will ensure optimal processes and result in reduced energy usage. In addition, leveraging advanced modeling and planning software optimizes operations and equipment, ensuring consistent product quality while using the least amount of energy.
Movicon Pro.Energy©
Achieve consumption goals with an open software solution that has complete connectivity, simplified monitoring, and robust data analysis capabilities.
Rosemount™ 403 Conductivity Sensor
Ensure fast response to conductivity changes between CIP clean and rinse cycles to conserve costs and optimize processes.
Aspen Mtell®
Get early and accurate warning of when equipment failure will occur, how the failure will occur, and what to do about it.
Frequently Asked Questions About Facility/Line Efficiency Optimization
Using software, such as DeltaV Spectral Process Analytic Technology (PAT), the critical quality attribute model can be run directly in the control system for real-time prediction and control, eliminating the need to take a sample off-line. For example, blending samples are critical to ensuring materials are mixed properly to minimize deviation and wasted materials. With the right software, you take a sample and adjust in real-time, greatly increasing production efficiency.
It is recommended to focus on optimizing materials, equipment, and people. This can involve leveraging software to predict demand and ensure the correct amount of materials are on hand. In addition, predictive maintenance should be in place to plan and schedule downtime so unexpected equipment failures don’t create deviations or bottlenecks. Dynamic real time updates to schedules need to be in place to accommodate the typical fluctuations encountered in production. By using the data and the model from a process, the bottlenecks can be understood. Additionally, “what if” scenarios can be run to determine how to alleviate the bottleneck and determine what would be the next bottleneck in production. Also, consistent operations are critical, so training personnel to handle unexpected issues in real-time results in smooth operations, with many challenges being prevented. A solution like AspenTech ProMV™ analyzes interrelated process data to identify production capacity degradation and determine potential issues before production is negatively impacted.
Balancing the supply and demand of materials, products, and resources is critical to staying on top of production in real time and understanding asset health. This involves having the right sensors, data analytics and predictive maintenance to monitor asset conditions, identify potential failures, and prevent breakdowns. In addition, taking an enterprise point of view with Emerson's Aspen Supply Chain Planner helps you holistically optimize your global supply chain by building optimal procurement, production, distribution, and inventory plans that meet demand and business revenue goals.
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