troduce modular equipment configurations. This approach provides remote access to production equipment and minimizes
the number of user interfaces in sterile process areas. Should
any workstation have a fault there is no longer a need to shut
down a process while the station is fixed or replaced. The flexibility offered by the wireless network and mobile workstations
provides a perfect backup system. Furthermore, when a new
product is being launched or a recipe changed, the mobile
stations can be moved throughout the plant as required. This
eliminates the need to install new operator stations.
Thanks to advanced wireless solutions, pharmaceutical
plants can reduce operating costs, better monitor critical systems; improve production efficiency, track assets, and support
decision-makers in making informed decisions in real-time.
IMPACT ON PLANT PERSONNEL
From field operators and controls engineers, to production
and maintenance technicians, wireless technology has a significant impact on personnel across the plant enterprise. It enables
workers to reliably perform all of their current tasks on mobile
devices hosted on a common grid that is shared with production units, sensors and control devices. The best illustration
of how wireless improves manufacturing performance comes
through the eyes of the actual people working on the plant floor
and having immediate access to data from operations.
For quality and production technicians, their daily routines
are improved by reducing the amount of time they spend
manually collecting data and later logging it into a database.
With wireless technology, the collection and entry processes
are automated, allowing the technician to spend more time
focused on areas with the potential for real added value.
Wireless reduces maintenance costs through better equipment monitoring and notifications. With thousands of assets
being monitored simultaneously, the maintenance engineer
can respond to a call by accessing equipment records and
maintenance procedures online, allowing the problem to
be diagnosed on the spot. The equipment’s status will be
updated and maintenance records will be logged — all while
the engineer is still on the plant floor — eliminating the
need for paper logbooks.
For the controls engineer, wireless technology offers
quick deployment and greater system agility, which is another key to a successful plant transition from a fixed configuration to a modular design. With wireless technology,
equipment modules can be installed and production units
configured without wiring and verification costs.
For the plant manager, the strength of wireless technology
is in its ability to lower both the initial capital cost of an automation project and the total cost of ownership while at the
same time providing immediate access to plant information.
The results are reduced operating costs and product losses.
TYPICAL END-USER EXPERIENCE
Like other pharmaceutical companies, Shire Plc. seeks to
economize its operations and still maintain the rapid sched-
ules necessary to get products out the door. The company re-
ceived FDA-approval for a new product and had to act quickly
to build a suitable manufacturing facility. The new plant was
designed to utilize disposable vessels and tank liners to reduce
the cost of cleaning and verification of process equipment.
Shire required technology to simplify scale-up from R&D
to commercialized production in order to manufacture its
new product as efficiently and reliably as possible. Several
alternatives were considered, but the company discovered
wireless stations would save money and help increase economies of scale in more ways than it imagined.
Shire selected Honeywell’s One Wireless network to provide
access to process data in a safe and cost-effective manner.
Based ontheISA100.11a standard, this industrial-grade solution
For 35 YEARS
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