High productivity and line availability are central priorities for pharmaceutical manufacturers. To provide more transparency and a better overview in production, Bosch will showcase its latest Industry 4.0 solutions for visualising and analysing machine data at Achema 2018.
Several machines and systems show how customers can use the starter edition of the pharma manufacturing execution system (MES) to easily monitor machine status and process parameters. In addition, downstream data services make it possible to troubleshoot error causes more quickly, and to ensure more consistent product quality.
“Bosch’s Industry 4.0 solutions are tailored to the special requirements of the pharmaceutical industry and deliver full transparency for all process and machine data,” said Dr Christian Hanisch, Project Manager Industry 4.0 for pharma at Bosch Packaging Technology.
“The ability to record and evaluate essential machine and process data helps our customers maintain high machine availability and performance – and to make real-time decisions based on hard facts.”
Bosch will also show how augmented reality specifically supports machine operators during commissioning or maintenance.
The Pharma MES starter edition with browser-based user interface consists of three main components: plant operators receive essential data on their overall equipment effectiveness (OEE), for condition monitoring of plant status or processes and on important events like alarms or downtimes, simply and in real time.
Visitors to Achema 2018 can experience the functions of the new Pharma MES Starter Edition firsthand on three machines: the new capsule filling machine GKF 720 and the new processing system SVP250 LF, combined with the filling and closing machine ALF 5000.
Using a clearly structured and intuitive dashboard view on the respective machines, the system displays information on essential machine and production data, such as number of filled containers or OEE.
The data is made available on the customer’s network via a web service and can be viewed on mobile devices or desktop PCs. This offers users maximum flexibility.
“Apart from individual machines, the Pharma MES Starter Edition can also monitor several lines simultaneously, and provides an important basis for optimum productivity,” Hanisch said.
To do so, the system records information from various production units and stores it centrally.
“To transfer data seamlessly, the Pharma MES Starter Edition is ideally calibrated for use with Bosch machines. However, with a suitable electronic interface, the solution can also be used with third-party production equipment,” he added.
The data gathered by the software can be subsequently analysed to lay the groundwork for process optimisations, for instance to enhance plant availability or performance.
Bosch also offers extensive data analysis services. The portfolio includes data mining, which Bosch has recently begun providing as part of the Pharma Service for solid dosage forms. With Bosch’s data mining tool, large amounts of data can be examined for the smallest effects using statistical methods.
Bosch will also demonstrate how commissioning and maintenance can be implemented more easily in future with its first augmented reality (AR) based instruction manual in the field of pharmaceutical development.
Operators are guided step by step through the Solidlab 1 laboratory system, from setup to process control. Additional information, such as calibration instructions and spare parts are displayed so that employees can quickly work with the system without the need for extensive training.