IIoT in Pharma Manufacturing and Use Cases

© Utthunga Technologies Pvt. Ltd. 2020
Utthunga for IIoT
IIoT Solutions in Pharma Manufacturing &
Use Cases
Presented by:
Utthunga IIoT Products Team

Company Overview
500+
PROFESSIONALS
12
Germany
USA
Japan
HQ & Development Centre:
Bangalore India
SERVICES SOLUTIONS
Product FOCUS
Engineering IIoT, Cloud & Big
Data Analytics
Embedded
Software
& Hardware
Digital
Services
Solutions
Quality
Engineering
Application
Software
Engineering
Process
& Factory
Power &
Utilities
Data
Connectivity
& Integration
Solutions
Custom
Solutions

Industry Associations
 Part of various Special Interest Groups
(Technical Specifications, Architecture,
Test & Certification and Marketing)
 Involved in reference Application
Architecture, Design and Development
 Technology Outsourcing Partner
 PROFIBUS and PROFINET Competency
Center
 FDT Test & Certification Center
 Part of Global Expert/Certified Community
https://opcfoundation.org/about/opc-foundation/experts/
https://www.profibus.com/pi-organization/certified-people/

Speakers for today
About the speaker
Monak Modi
Monak has a unique combination of educational background
in the form of Instrumentation at UG Level and MBA in Energy
management
He has total of 4 years of experience in the field of automation
and IIOT Solutions management.
He has provided solutions in industry segments including
Pharma, Manufacturing, Steel & Cement, Foundry and
Consumer goods industries.

Utthunga’s Capabilities in Automation and IIoT
INTEGRATION SOLUTIONS
INDUSTRIAL AUTOMATION
INDUSTRY SOLUTIONS
• Connectivity: Sensors, Edge devices
Gateways
• Integration Solutions - Protocol
drivers, OPC Classic & UA, Cloud,
SCADA, ERP and MES• Field Instrumentation
• PLC/DCS/SCADA Automation
systems
• Engineering software
applications
• Operations management
solutions
• Integration and simulation
solutions
• Asset Insights
• Operation Efficiency & Analysis
• Energy Analysis & Optimization
• Predictive & Prescriptive Maintenance
• Remote Monitoring/Diagnostic

Agenda
4. Major Bottleneck- Pharma Utilities
3. Pharma- API Use cases
2. Pharma Manufacturing- Current scenario
1. Introduction about Industry 4.0 Concept
6. Utthunga’s Solutions
5. Pharma- Formulation and Drug manufacturing processes
7. The partners in Pharma Manufacturing-IOT- Leveraging expertise together

Introduction about Industry 4.0 Concept
Industry 4.0 for pharma manufacturing means transforming the
manufacturing workforce. From connecting workers, to more
human centred work-flows to shift culture and values of an
organisation.
Computerization
Connectivity
Visibility
Transparency
Predictability
Adaptability

Concept of industry 4.0
IIOT- networking of
disparate systems,
Sensors, People
Cyber Physical
Systems- Combines
Human and
Machine Inputs

Quick Polls

Current Pharma Manufacturing Scenario
Product Quality Operational
Efficiency
Improvement
Regulatory Compliances
and Stringent Documentation
requirements
Major Priorities
Data Integrity

Current Pharma Manufacturing Scenario
Product
Degradation
and Recalls
Compliance
related to
GMP and GDP
Higher
operational
Costs
Issues Automation in Processes
Enterprise Applications
(MES, ERPs)
Electronic Batch Records
Warehouse Management Systems
Existing Infrastructures to address Issues

Pharma Manufacturing – API Processes(Key Points)
MIXING
Solvents and
Chemicals
ISOLATION
From
Solvents
Steam, Chilled
Water/Cooling
water
Water
Removal
Vapour
Drying
Air/
Nitrogen
Reactor utilities:
• Brine Solution
• Hot water
• Cold Water
• Steam
• Nitrogen

Pharma Manufacturing – API (Use Cases)
Need of a business:
Increase manufacturing efficiency
Method:
Reduce equipment downtime and trend analysis of all pressure and temperature
parameters and data analytics tools to get better insights on operation
IOT Solutions
• Smart equipment that collects operational data and status (run time, temperature,
load, ready to use/in operation/under cleaning/under maintenance).
• Add sensor packs to collect device data; build a back-end platform using industrial
IoT platforms
• Run analytics on the data to predict when a piece of equipment might break down.
(Pumps/Motors etc)
• Automate incident requests triggered by integration with ticket management
systems.
• Sensors that collect metadata for analysis to identify and reduce causes of process
variability
Benefits:
• Better equipment utilization and less downtime.
• Improved productivity, efficiencies, and cycle time.
• Increased production yield.

Pharma Manufacturing – API (Use Cases)
Need of a business:
Maintain Utility equipment up and running at desired Operating Conditions with low down-
times- Reactor Motors, Pumps , Chillers, Nitrogen Plants(Compressors) at higher energy
efficiency
Method:
E-Log books
Track Consumption pattern and other Performance Parameters to Predict failure.
IOT Solutions
• Digital Logbook solution where operator can enter all the records through TAB/ HMIs.
• Tracking batch records on the go
• Visibility into all the critical parameters at the time of any abnormal condition
• Master database creation to rectify major issues occurred in the past –
• Work Order provided with Task description & sequence
• Real time visibility into performance of these Pumps and reactor motor efficiencies
• Predictive insights on reactor and pump motor
Benefits:
Reducing human errors.
Helps in decision making
Reduces down-time and batch losses due to operational issues don’t occur
Temperatur
e Sensor

Pharma Manufacturing – Utilities
Oil free compressors are to supply to clean and purified air to
keep your pharmaceutical products sterile, clean, aerated and
safe during manufacture, storage or moving.
HP, LP and MP steam to dry the granules, sterilize equipment
and to heat the reactor solutions to make API
Chilled water systems are necessary to maintain proper and required room conditions
like Temperature, Humidity, Air quality in Terms of Class contentiously.
Pumps are necessary to provide utilities at desired flow and pressure to the facility
AHU must provide more air into the cleaner space than is mechanically removed from
that same space.
The primary use of large, industrial cooling towers is to remove the heat absorbed in
the circulating cooling water systems used in various Industrial Plants.

Pharma Manufacturing – Utilities (Use Cases)
Need of a business:
Tracking KPIs and predict the failure of critical components of these utility equipment.
Get actionable insights on the maintenance activities
Method:
Real-time monitoring of dependent variables like suction pressure, discharge pressures
and correlating them with performance parameters like COP, ikw/TR , cfm etc.
IOT Solutions
• Smart equipment that collects operational data and status (run time, temperature,
load and create digital twin of an equipment to create set of rule engines)
• Real time visibility into performance of boilers, chillers, compressors etc
Benefits:
• Reduction in Maintenance costs
• Track Asset’s remaining useful life(RUL) and achieve better ROI
Temperature
Sensor

Pharma Manufacturing – Utilities (Use Cases)
Need of a business:
Energy efficient equipment without compromising on the work to be delivered
Method:
Real-time monitoring of dependent variables like suction pressure, discharge pressures
and correlating them with performance parameters like COP, ikw/TR , kw/cfm etc.
Energy benchmarking on various equipment and define SEC goals year on year to track
the progress on real time basis
Energy balance across facilities.
IOT Solutions
• Smart metering across all critical equipment and define energy efficiency measures
based on ROIs.
• Identify savings based on Power parameters like Harmonics, Voltage and Current
imbalances and loading.
• Real time visibility into performance of boilers, chillers, compressors
etc(kw/cfm,ikW/TR etc)
• Define your reporting requirements to create MES report for tracking various
financial KPIs.
Benefits:
• Reduction on energy cost to improve bottom-line because in pharma major
bottlenecks are utilities

Quick Polls
Utthunga OPC Services

Pharma Manufacturing – Formulation(Key Points)
WEIGHING
AND
BLENDING
GRANULATION DRYING
LUBRICATION AND
COMPRESSION
• Cross Contamination is the major concern
• Equipment Down time is critical.(Can lead to entire batch
scrapping)

Pharma Manufacturing – Formulation(Use Cases)
Need of a business:
• Increase Manufacturing Efficiency , -
• Visibility into all the major Batch records and Maintenance measures
Method:
• Reduce variability and improve yield
• Line Clearances indications
IOT Solutions
• Smart equipment that collects operational data and status (run time, temperature, load, ready to
use/in operation/under cleaning/under maintenance).
• Sensors that collect metadata for analysis to identify and reduce causes of process variability and
improve production yield.
• Visibility into human and material movement across the shop floor through tracking and
monitoring technologies
• Interactive, digital line clearance applications can make line clearance easier to navigate. Digital,
IoT enabled work instructions guide users through SOPs, increasing efficiency ensuring that work
is performed correctly and validated automatically.
Benefits:
• Real-time dynamic scheduling of shop-floor activities.
• Better equipment utilization and less downtime.
• Ability to track overall equipment effectiveness (OEE).
• Improved productivity, efficiencies, and cycle time.
• Increased production yield.

Pharma Manufacturing – Warehouse Operations(Use Cases)
Need of a business:
Maintain Desired Storage Conditions
Increase operational efficiencies in the ware-houses
Method:
Track storage conditions of sensitive drugs.
Optimize the movement of warehouse assets
IOT Solutions
Environmental sensors collect data in temperature-controlled areas of the warehouse to
track environmental conditions in real time. (drugs(Dust particles, temperature , Relative
Humidity)
Active and passive logger data is compared with thermos stability tables to generate
alerts in the event of temperature excursions.
Sensors on product/holding items transmit information on product location, inventory
and inconsistencies directly to the warehouse manager’s handheld device/ dashboard.
Benefits:
• Less drug expirations and degradations from temperature excursions

Utthunga’s Solutions

E-logbook or Digital Logbook( Utility Maintenance- Formulation Machines)
Logbook maintenance for every process is becoming huge and time
consuming task for Manufacturing, Pharma and other companies. Use of
manual logbooks, printing, maintenance and continuous track are tedious
and resource intensive tasks.

Asset Health Management & Analytics (AHMA)- Chillers, Compressors, AHUs,
Pumps, Boilers, Critical Production Machines

Asset Health Management & Analytics (AHMA)

Drive Monitoring (VFD)- Pump, Compressor , Reactor Motors

KPI Management( Across Facilities)
 KPI Configuration
 Defining different types of KPI
 Business
 Availability
 Quality
 Process
 Performance
 Energy
 Productivity
 Utilization
 KPI Trends
 Actions for improvements
 KPI Hierarchy

Predictive Maintenance( Critical Assets- Chillers, Reactors,
Compressors, Pumps)
 Uses AI/ML Models for prediction &
forecasting
 Python based framework with Google Tensor
flow, RNN and other models, algorithms
 Prediction based on the Asset and Sensor
parameters
 Identification of Time To Failure
 Notifications based on the TTF
 Predictive Maintenance Alarm history

Utthunga’s Industrial Network related Solutions( API Manufacturing)-
Profibus , Profinet, Ethernet/IP etc.
Business division
Services
System availability through reliable communication
■ Survey measurement/
Certification of fieldbus
networks
■ Inspection measurement
■ Troubleshooting
■ Commissioning
■ Training
■ Network planning
■ Documentation
■ Commissioning
■ Monitoring tools
• INspektors®
• Software PROmanage®
■ Diagnostic tools
■ Infrastructure
components
For questions about
technical solutions:
■ Telephone Support
Business division
Consulting/Support
Business division
Products

The Partners in Pharma 4.0-Leveraging expertise to grow together
IOT Pharma 4.0
Major
Pharma
OEMs
Utthunga
Technologies(IOT
Enabler)
operational
Excellence
Team
Database
management
System(SAP,INFOR,
MS,FRP etc.)
Pharma
Consultants
Technical
trainings and Skill
development
and Cultural
change

IIoT Webinar Series Calendar
17 July 2020 : Condition Monitoring using Vibration & Electrical signature in process Industry-
19 June 2020 : OEE & performance analytics in discrete Industry
5 June 2020 : IIOT Solutions for Pharma Manufacturing and Use cases
31 July 2020 : KPI Management
3 June 2020 : IIoT Relevance to your Industry

Utthunga Technologies Pvt. Ltd.
No. 8, 27th Cross, 2nd Stage,
Banashankari, Bangalore – 560 070
Phone: +91-80-68151900
Mail: contact@utthunga.com

IIoT in Pharma Manufacturing and Use Cases

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