Europhartech Implements Holistic Fully Integrated Serialization Project

Rockwell Automation proposed a configurable and pre-validated base solution, which significantly reduces implementation time. The serialization solution is based on its Rockwell Software® PharmaSuite® MES platform, using a client-server architecture running FactoryTalk® View Site Edison (SE). The Product Management Client (PMC) is designed as a module of the PharmaSuite MES and acts as an operator-interaction screen. Unlike many solutions designed and developed from Tier 1 systems, the Rockwell Automation serialization solution is designed as a Tier 3 specific module. It therefore benefits from the ability to interface with other ERP and MES suites, as well as line controllers and lower-tier machines.

From an automation perspective, the project employs an Allen-Bradley® ControlLogix® programmable automation controller (PAC). This is powerful processor that is specified due to the large amounts of serialisation data it needs to store. Should the serialisation server fail, the PAC can run autonomously using the pre-downloaded data. Allen-Bradley CompactLogix™ PACs can also be used if a full batch download is not required. Due to the Logix range’s scalability, very little effort is required to change controllers.

Visualisation and operator interaction is provided by an Allen-Bradley VersaView® industrial computer, Although FactoryTalk View does not normally need a computer equipped HMI, in this instance more functionality was required as was the need to run parts of the PharmaSuite client on screen. The PLC and motion solution can also be controlled from this interface.

For product movement and orientation, the serialisation solution deploys several Allen-Bradley Kinetix® servo drives. These are used to control both the upper and lower belt rotation, the vertical position of the upper belt (to cater for varying box sizes) and the two-axis printer head. Servo delivered accuracy is important to synchronise printing and the application of the tamper evidence solution. This accuracy is coupled to the flexibility need to cater for a variety of box sizes, with simple re-programming or recipe selection via the HMI.

The Rockwell Automation solution is also scalable, and can adapt depending on the needs of Europhartech. For example, centralized serial number management and tamper-proofing, which the PMC allows, can be extended to aggregation. The randomized serial numbers, supplied by the company's ERP system, are sent to the workshop via the MES where the PMC module will process them. The PMC also supports main recipes and packing orders.

Europhartech also chose a predictive maintenance solution from Rockwell Automation, which will be used to reduce or even eliminate faults, a major boost for the group, whose production is performed on a just-in-time basis, operating on a 3 x 8-hour shift basis, sometimes seven days a week.

This new data architecture, delivering more robust internal and external communication, has taken Europhartech into the arena of the Rockwell Automation Connected Enterprise, an approach which converges plant (OT) and enterprise (IT) networks, and securely connects people, processes and technologies. As well as addressing upcoming serialisation regulations, it also covers all primary facets of an Industry 4.0 approach and, in this instance, Pharma 4.0.

RESULTS

Of the five lines to be modernised, the first was upgraded in March 2018, with final roll-out scheduled for November 2018. Europhartech started with serialization and tamper-proofing, preferring to postpone aggregation until it is more familiar with the new tool. It also wished to test its potential in order to refine the settings under varying real-life conditions, comprising successive batches of different medicines.

Europhartech will be ready to meet all the requirements of current and future regulations by June 2018, giving it a significant competitive and commercial advantage, and improving serialization information exchange with its partner customers. Its maintenance teams already appreciate the design of the module, including front-facing label projection. They also welcome the line's agility, which manufacturing/process line switching easier than before.