RtReports in Action Barry Higgins Automation & Control Engineer

Presentation Agenda  Introduction.  Overview on PI in Janssen.  Batch reporting - current situation.  RtReports - an introduction.  One data source - multiple views.  Internal Customer reaction.  Future Developments.

Introductions  Janssen Ireland based in Co. Cork.  Over 230 people employed.  Manufacture Active Pharmaceutical Ingredients for human use.  Imodium, Risperdal, Haldol.  Batch Site.

Introductions  Barry Higgins - with Janssen for over 12 years.  Worked in Production, Technical Support, Automation.  Automation and Control Engineer. - Emerson RS3, ABB Sattline and Industrial IT.

PI in Janssen  First introduced to site as part of SAP integration project in ‘99. RLink.  Over 2000 tags.  ProcessBook main user interface.  Users - Operations, Engineering, QA, Environmental, Security.  Uses - Batch release, Process Investigations, Process Improvement, Energy Management, Alarm Management, SAP confirmations, Quiet Time Monitoring.

Current Situation at Janssen  Hybrid batch record. Paper batch book with over 100 operator written inputs and sign offs required per batch book. Control system reports and trends printed off and signed off and sent to QA as one package.

Before Installation  Look at the current situation.  Talk to your internal customers.  Module database - Batch Structure.  Sit down and discuss with install team, the type of reports you want.  Installation is quick and you will be generating reports within a day.

RtReports  Secure.  Web based batch reporting tool.  Reports are based on the plant configuration, specs and production data.  Components -. Data Template Admin Tool. Format Template Admin Tool. RtReports generator.  Uses the Module database.

One Source - Multiple Views  Reports can be configured for each customer.  Customers can be given the data they need at their desktops.  Reports can be generated while batches are running.

RtReports Types of reports. Production summary reports. Detailed production reports. Exception reports. Cycle time reports. Shift activity reports.  All from the same data source !!!

Building the Data Template  First step.  Modular approach. - Define what data you require from each phase.  Reduces validation time. - Only need to validate once.  Test before publishing.  Format template will extract the data.

Pre-Defined Actions  Reuse configuration in more than one location or template.  Can be a complex or simple.  Ideal for complex actions, just create it once.  Allows for site specific situations to be catered for.  Allows you to build data templates much more quickly.

Pre-Defined Action Editor

Pre-Defined Actions  Same action used in different locations.  This allows templates to be built quickly with minimum configuration.

Format Editor  Data Journal  Formats information  Displays in the Report Viewer.  XML.  Preview HTML before releasing.

RtReports at Janssen  Beta site - Nov ‘03.  Generating reports within hours.  Building more detail into control system.  Customising reports for different customers.  Not just typical product quality reports.  Shift based reports - gives the current status of the plant.

Example

Multiple Report Types

Example Report

Same Data Different View

Internal Customer  Reactions –Benefits can be seen straight away. –Reduction in product release cycle time.  Concerns –Paper, paper, paper. –Validation workload.

Future Developments  New front end tools.  Start validating reports.  Begin removing manual operator inputs.  Develop reports for non process related areas.