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Pharmaceutical Manufacturing Automation with WinCC OA

POSTED 12/14/2023

Summary

DMC partnered with a client in the pharmaceutical industry to provide plant-wide automation of a new facility. DMC performed custom PLC and SCADA programming, integrated dozens of OEM systems, and provided onsite commissioning and qualification support.

Solution

This client was undertaking a large project to build and launch a new pharmaceutical manufacturing and test facility. As part of this effort, the client required system integrator services to provide design, engineering, commissioning, and qualification for a variety of manufacturing utility, monitoring, and process systems. DMC was uniquely qualified to provide these services due to our extensive experience with pharmaceutical manufacturing automation, and technical expertise with the selected platform (Siemens WinCC OA Open Architecture or "WinCC OA").

WinCC OA SCADA Configuration and Integration

DMC utilized WinCC OA to provide a centralized interface for plant control and monitoring. DMC utilized Redundancy in WinCC OA to meet the high availability requirements of the plant. A custom user interface was developed utilizing high efficiency HMI design principles. This system provided key features such as data acquisition and archiving to Oracle database, alarm monitoring and SMS/email notification, and audit trail functionality for regulatory compliance (21 CFR Part 11).

Electrical Design and Build

DMC worked with partners to design and build electrical panels for a variety of systems. The panels met the client's requirements including NEMA, UL, and safety requirements. As a close Siemens partner, DMC worked with Siemens application engineers to select the hardware necessary to meet the client's needs.

PLC Programming

DMC designed and implemented PLC programs for the facility's manufacturing utilities and monitoring systems. Successful integration required close coordination between DMC and our client’s process and controls engineers.

OEM Equipment Integration

DMC integrated dozens of OEM vendor systems into WinCC OA for data acquisition and monitoring. We reviewed vendor code and integrated a variety of systems utilizing WinCC OA's extensive communication drivers to communicate with many different platforms (Siemens, Rockwell, GE iFix, Wonderware/AVEVA, etc.).

Documentation and Regulatory Compliance

Throughout the project, DMC followed Good Manufacturing Practice (GMP) guidelines to ensure quality standards and meet regulatory guidelines. We generated software and hardware test plans during the development cycle, wrote qualification documents for installation and operation qualification, and provided onsite support for equipment commissioning and qualification.

Customer Benefits

  • Project flexibility
  • Qualification Support
  • Regulatory compliance
  • Electrical design and build
  • PLC and SCADA development
  • Redundant SCADA deployment
  • Long term (permanent) data storage

Technologies

  • Siemens SIMATIC WinCC OA
  • Siemens S7-1500
  • Siemens TIA Portal
  • Rockwell ControlLogix
  • Rockwell Studio 5000
  • Oracle Database

Learn more about DMC’s WinCC Open Architecture Development expertise and contact us today for your next project.