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© 2007 ABB Group PAT – Turning Data into Knowledge Chris Hobbs APACT Glasgow May 2009
© 2007 ABB Group Slide 2 Turning Data Into Knowledge Why QbD and Why PAT ? What are the Data Handling Challenges ? Managing Analyzers Managing Process and Analytical Data
© 2007 ABB Group Slide 3 EMEA USA Times are changing in pharma manufacturing Increased pressure on cost, time and innovation with fewer and fewer new drugs issued Companies have to re-invent the balance between quality and compliance Most regulator agencies work with industry to reinvent innovation and ensure more affordable drugs Why QbD and Why PAT ? Slow down in R&D innovation combined with patent expiration on 19 blockbusters Projected $40 Billion in lost revenue for the top 10 pharmaceutical manufacturers
© 2007 ABB Group Slide 4 Why QbD and Why PAT ? Manufacturing Objectives Produce The right quality In the shortest time At the lowest cost Predictable fashion Life Science Manufacturing Does not always meet all criteria Efficiency is lower than comparable industries Higher variability than what is desired PWC, Deming, etc Stop inspecting, correct problem at its root Lots of room for improvement that requires a new way of working.
© 2007 ABB Group Slide 5 Why QbD and Why PAT ? A change in the guidance issued by the FDA, allows pharmaceutical companies to take a quantified science and risk based approach to drug manufacture by the use of online analytical technology. This allows Better understanding of the process Reduces the time to market Reduces production costs Flexibility in product production and pricing
© 2007 ABB Group Slide 6 Why QbD Why PAT ? A more flexible approach Understand Process Variations A process is well understood when: All critical sources of variability are identified and explained The resulting process upset from input variability is recognized Product output based on inputs and process can be accurately and reliably predicted Control outputs from input variability by: Identifying and measuring Critical Quality Attributes (CQAs) Measure of product properties such as identity, strength, potency, purity, particle size, homogeneity and moisture Identifying and controlling Critical Process Parameters (CPPs) Parameters that have affect on CQAs such as valve set points, agitator speed and pump speed
© 2007 ABB Group Slide 7 Objectives Encourage innovation and efficiency improvement Improve the understanding of manufacturing processes by implementing analytical solutions at/on/in-line Economic Benefits Reduced cycle times Increased equipment utilization Reduction in warehousing requirements (quarantine) Reduced time to market Change purely batch process into continuous manufacturing process Reduced QA/QC costs Quality Benefits Higher product inspection rate Reduced process errors Decreased product exposure for operators Improved product consistency Promotes continuous improvement in a regulated process Why QbD Why PAT ?
© 2007 ABB Group Slide 8 Turning Data Into Knowledge Why QbD and Why PAT ? What are the Challenges ? Managing Analyzers Managing Process and Analytical Data What are the Data Handling Challenges ?
© 2007 ABB Group Slide 9 What are the Data Handling Challenges ? Use the information Monitor process PAT in Manufacturing Extract process understanding Use data to control the process Use data for real time release Extract physical and chemical understanding Use knowledge to improve scale up and transfer to production Improve development cycle PAT in R&D Use knowledge to improve process K K K = gain knowledge
© 2007 ABB Group Slide 10 What are the Data Handling Challenges ? The three stages of PAT LEARN – Gather data from analysers and process instruments to better understand the process PREDICT – Create a model which will predict Quality Attributes. Use the predicted value to advise operators when quality deviation occurs or when a process is complete. Validate with lab tests CONTROL – Directly control the process according to the predicted Quality Attribute. Validate with lab tests Data Knowledge Benefit Information
© 2007 ABB Group Slide 11 What are the Data Handling Challenges ? There are many Analyzer manufacturers Each Manufacturer has their own interface and client software Analyzers can be used to perform more than one type of analysis Multiple analyzers may be required in order to control product quality. Analyzer data needs to be synchronized with other analyzers and or the control system. The quality prediction and its raw data needs to be associated with batch of pharmaceutical being manufactured according to FDA rules. (Electronic signatures, long term storage, common formats etc….)
© 2007 ABB Group Slide 12 What are the Data Handling Challenges ? Analyzers produce multiple disparate formats e.g. Spectra, Bar Graphs, Chromatographs, Images etc. An analyzer model can be used to predict many different properties. Not all analyzer measurements are in real time. In order to interpret data from multiple analyzers the measurements need to be correlated. Data collected needs to be made available to various offline platforms e.g. modelling packages, LIMS, EBRS etc
© 2007 ABB Group Slide 13 What are the Data Handling Challenges ? Key Concepts for Data Management Multi-Analyzer Management Analyzer configurations for multiple analyzers are stored in one location and integrated with PAT Method Provides a Platform for executing multi-instrument models. Diagnostics and Reference information to be stored Structured Data Storage (Batch ID, Note Book No., Stock Unit, Order No.) Univariate and Multivariate data from multiple Instrument platforms SCADA/DCS process data. Method Execution provide Audit Trail, Alarm and Event Central Model Management Data Integrity PAT Method Data to be archived by PAT Method reference number. Off-line storage based on reference number Data Access Local client for Method management and Method execution Make data available to existing operator screens. (SCADA / DCS) Remote Client support for data analysis and display using purpose built data applications Data may be extracted by different off the shelf standards. (OPC, ODBC, ODA, SQL) Standard tools available for visualization Configure, Manage, Execute, Store and Analyze
© 2007 ABB Group Slide 14 Turning Data Into Knowledge Why QbD and Why PAT ? What are the Data Handling Challenges ? Managing Analyzers Managing Process and Analytical Data Managing Analyzers
© 2007 ABB Group Slide 15 Managing Analyzers Analyzer integration for solutions such as the Process Analytical Technology (PAT) Initiative presents a unique set of integration challenges for data exchange and control. There is a large variety of analyzers types, from various vendors with many different types of data, including complex arrays and structures. There are many different ways to integrate analyzers and execute control from external systems. New process optimization opportunities exist that require unit and system level coordination and control of multiple analyzers from different vendors. No standard data model exists for different classes of analyzer. All solutions are purpose-built. Standard interfaces drive down the validation costs for project implementation in the pharmaceutical industry. Initiatives such as PAT are driving analyzer integration and the best way to accomplish this is via open standards.
© 2007 ABB Group Slide 16 Managing Analyzers - Existing Standards for analyzers Data exchange standards Driven by the need to store analytical data for laboratory instruments Increasing Transportability Increasing Information Content Original Raw Data From Instrument Workstation Software Plots & Graphics GIF, HPGL, Metafiles, Scanned Printouts Textual Results Peak Areas, Positions, Concentrations Full data and results Can only be read by instrument workstation software Eventual instrument obsolescence is a problem Can be displayed with viewer software Cannot reprocess, manipulate, or interact with the data Cannot compare data Can be displayed with nearly anything (paper, word processor, etc.) Totally disconnected from the raw data
© 2007 ABB Group Slide 17 Managing Analyzers – Examples of Current Interfaces ABB FTIR: Provides a DLL that gives access to instrument functionality with a series of method calls Bruker Matrix-F: Provides a DLL that gives access to instrument functionality through a generic 3 letter ASCII command code Mettler-Toledo FBRM: No DLL or driver of any form, need to use proprietary RS232 protocol or full laboratory FBRM software CDI Diode Array: Provides an OPC/DA interface with tags for array data, scalar data and instrument control Mettler-Toledo MonARC: Embeded computer provides access to commands and data through SQL server databases
© 2007 ABB Group Slide 18 Typical Dryer Application Learn: What is happening while we dry Predict: Use the data to get moisture Control: Change the process to get what we want Moisture Dryer NIR Analyzer Hot Air Granules Filters
© 2007 ABB Group Slide 19 Integration at Process Controller is expensive and proprietary Integration at Process Controller is expensive and proprietary Limited data types from analyzer controller to process controller in non-standard format Limited data types from analyzer controller to process controller in non-standard format Hot Air Granules Filters FBRM Analyzer NIR used to monitor moisture Determine end-point Moisture profile used for asset monitoring Provide data to allow closed loop control to optimize drying FBRM used to monitor particle size Detect prevent clumping Detect presence of fines that can clog filters Provide data to allow closed loop control to optimize drying Proprietary interface Proprietary Interface Current Analyzers in the Process Proprietary Interfaces – Non Standard Data NIR Analyzer Analyzer Controller Analyzer Controller Process Controller (PLC, DCS) ProprietaryinterfaceProprietaryInterface
© 2007 ABB Group Slide 20 Managing Analyzers The current status quo is unsustainable Analyzers show too much variation in their interfacing capabilities Validation of software with this level of variability is difficult We need a new standard for Analyzer Interfaces. A standard which Provides a consistent way to create interfaces Allows the interfaces to be reused by multiple software packages Desired Characteristics Define the notion of analyzer class (Spectrometer, Liquid Chromatograph, Particle size, Mass Spectrometer, …) Within a class should be entirely data driven (no code changes In the base platform) Needs to support high data volumes on a Network (imaging)
© 2007 ABB Group Slide 21 Managing Analyzers – OPC-ADI OPC Foundation Announces Support for Analyzer Devices Integration into OPC Unified Architecture Platform Press Release dated January 12, 2008 The OPC Foundation has announced support for Analyzer Devices Integration into the OPC Unified Architecture. The OPC Foundation has created a working group composed of end-users: Abbott, GSK,Pfizer and vendors: ABB, Mettler-Toledo, Umetrics representing both Process Analytical Technology (PAT) and laboratory industries to develop the information model for all analyzer devices facilitating plug- and-play multivendor interoperability. The Analyzer Device Integration Working Group will develop a common method for data exchange and an analyzer data model for process and laboratory analyzers. The model will be developed as a logical extension of the OPC UA specifications. Analyzer integration based on standards will offer unique opportunity in Data Management & Integration for solutions such as Process Analytical Technology (PAT).
© 2007 ABB Group Slide 22 Vision In the same way that field device standards have driven the widespread adoption of intelligent field devices in the process industries, the ADI standard will promote the use of high level analyzers in manufacturing processes. The ADI standard will provide a single model for analyzer vendors to create and distribute device drivers that expose the capabilities of process and laboratory analyzers using the universally accepted, platform-neutral OPC UA standard. These drivers shall allow complete access to all low level and high level analyzer data and be compatible with regulated manufacturing environments. OPC UA is being adopted as the basis for the ADI standard because It is a platform neutral standard. Drivers can be implemented on any operating system or embedded in any networked device It is designed to support complex data types and object models Designed to achieve high speed data transfers using efficient binary protocols. It has broad industry support beyond process automation and is being used in support of other industry standards such as S95, S88, EDDL, MIMOSA, OAGiS Toolkits are available to support the creation of OPC UA drivers and applications. Managing Analyzers – OPC-ADI
© 2007 ABB Group Slide 23 Managing Analyzers – OPC-ADI Level 1 – Univariate data integration In this model only predicted properties are collected Level 2 – Multivariate data integration In this model predicted properties and raw data are collected (spectra, chromatograms, histograms) Level 3 – Full Instrument control In this model the central system holds the analyzer configuration Control Data Management An Architecture for Integration Instrument Standard Control Level 3 is the enabling technology for integration of high level analyzers Provides central coordination/control of all analyzers Provides a single validated interface to all analyzers Provides central storage of all RAW analytical data Instrument
© 2007 ABB Group Slide 24 OPC UA Base Services All Necessary Services Managing Analyzers – OPC-ADI DAA&EHDACMDs OPC Information Model OPC-ADI is one of many OPC UA Information Model Extensions OPC-ADI Analyzer Device Interface Vendor Information Model
© 2007 ABB Group Slide 25 Integration at Process Controller is standard and easier Complex data types available from analyzer controller to process controller in a standard format Hot Air Granules Filters FBRM Analyzer NIR used to monitor moisture Determine end-point Moisture profile used for asset monitoring Provide data to allow closed loop control to optimize drying FBRM used to monitor particle size Detect prevent clumping Detect presence of fines that can clog filters Provide data to allow closed loop control to optimize drying Proprietary interface OPC-ADI Analyzers in the Process Standard Interfaces – Standard Data Smart NIR Analyzer Controller Process Controller (PLC, DCS) ADI interface ADI Interface Managing Analyzers – OPC-ADI
© 2007 ABB Group Slide 26 Current Members ABB Abbott Arla Foods BR&L Consulting CAS FOSS GlaxoSmithKline Kaiser Optical Systems Malvern Instruments Mettler-Toledo Autochem Novartis OPC Foundation Pfizer Siemens Software Toolbox Sympatec GmbH Thermo Fisher Scientific Umetrics Yokogawa
© 2007 ABB Group Slide 27 Timeline February 2008 – kickoff Scheduled meetings December 2008 - planned draft release June 2009 – planned first release Reference implementation Q1
© 2007 ABB Group Slide 28 Turning Data Into Knowledge Why QbD and Why PAT ? What are the Challenges ? Managing Analyzers Managing Process and Analytical Data
© 2007 ABB Group Slide 29 Managing Process and Analytical Data GranulatorFluid Bed DryerTablet PressCoater NIR : Monitoring end point predication of moisture content for drying phase. FBRM : Measures particle sizes. NIR : Monitoring coating thickness PVM: Particle Size RAMAN: API Concentration PAT System
© 2007 ABB Group Slide 30 Historical Storage Managing Process and Analytical Data - Structured Data PAT Method / Experiment Array Data, e.g. spectra … Model Predicted Values Process Data SOP Platform Neutral Record (XML, CSV, PDF…) Binary Format Spectral Data Image Data CSV Data Numeric Data Alarm & Event Audit Trail Instrument Configurations (Data Model) Lab Results Execute PAT Method Data
© 2007 ABB Group Slide 31 Managing Process and Analytical Data - Structured Data PAT Method Procedure Unit Procedure Unit Operation Unit Procedure Instrument Definition PAT Method Moisture Data Definition Particle Size PAT MethodBatch system Unit Operation Use S88 Batch Model to structure data
© 2007 ABB Group Slide 32 Managing Process and Analytical Data – Data Access Uses S88 Batch model to structure and track data Integrates Process control with Analyzer management Uses industry standard protocols for all interconnections Batch Manager SCADA Historian SCADA OPC Server SCADA PLC SCADA I/O Analogs & Digitals Time Based Trends Alarm & Event OPC/DA (Analogs & Dig.) Dryer NIR Analyzer Visualization Clients Analyzer Data Acquisition Paticle Analyzer Particle Size Model Moisture Model PAT Data Manager Combined Particle / Moisture Model Data By Batch ID Chemometric Analysis Workstations Hot Air Granules Filters No current complete standard; OPC-ADI foreseen for this
© 2007 ABB Group Slide 33 Managing Process and Analytical Data – Data Access Data must be correlated
© 2007 ABB Group Slide 34 Managing Process and Analytical Data – Data Access
© 2007 ABB Group Slide 35 What are the Data Handling Challenges ? Key Concepts for Data Management Multi-Analyzer Management Analyzer configurations for multiple analyzers are stored in one location and integrated with PAT Method Provides a Platform for executing multi-instrument models. Diagnostics and Reference information to be stored Structured Data Storage (Batch ID, Note Book No., Stock Unit, Order No.) Univariate and Multivariate data from multiple Instrument platforms SCADA/DCS process data. Method Execution provide Audit Trail, Alarm and Event Central Model Management Data Integrity PAT Method Data to be archived by PAT Method reference number. Off-line storage based on reference number Data Access Local client for Method management and Method execution Make data available to existing operator screens. (SCADA / DCS) Remote Client support for data analysis and display using purpose built data applications Data may be extracted by different off the shelf standards. (OPC, ODBC, ODA, SQL) Standard tools available for visualization Configure, Manage, Execute, Store and Analyze
© 2007 ABB Group Slide 36
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