Reducing Human Error in GMP with Automation
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The document discusses how automation and digitization can help reduce human error in Good Manufacturing Practices (GMP), which currently accounts for nearly a quarter of unplanned downtime in manufacturing. It emphasizes integrating systems to eliminate manual data entry, capturing real-time data, and applying high-performance techniques to enhance operational efficiency. Various strategies, such as utilizing edge computing and modern browsers, are outlined to improve data access and decision-making in the manufacturing process.
Reducing Human Error in GMP with Automation
- 1. Beyond Compliance Reducing Human Error in GMP with Automation
- 2. The Sponsor ✔ ✔ ✔ Plant Management Platform BEYOND COMPLIANCE
- 3. About the Presenter BEYOND COMPLIANCE Aaron Bolshaw VP of Marketing Travis Cox Co-Director of Sales Engineering ● Experience with HMI (Human Machine Interfaces) and SCADA (Supervisory Control and Data Acquisition) projects ● Former Director of Training
- 4. Before we get started BEYOND COMPLIANCE Helpful tips ✔ Informal, conversational approach ✔ Ask Questions (Q&A at end) ✔ Only panelists are displayed/heard ✔ Recording link will be shared ✔ Slides will also be shared ✔ Audio issues? Use call-in number
- 5. About Inductive Automation About Inductive Automation • Founded in 2003 • Founded by experienced system integrator • HMI, SCADA, MES, and IIoT software • Highly diversified customer base across many industries • Over 2,200 integrators • Used by 48% of Fortune 100 companies Learn more at: inductiveautomation.com/about Our mission is to create industrial software that empowers our customers to swiftly turn great ideas into reality by removing all technological and economic obstacles.
- 6. Ignition: Industrial Application Platform One Universal Platform for SCADA, MES & IIoT • Unlimited licensing model • Cross-platform compatibility • Supports containers • Based on IT-standard technologies • Scalable server-client architecture • Web-managed • Web-launched on desktop or mobile • Modular configurability
- 7. Reducing Human Error In GMP Manufacturing • People Are Human • The Blame Approach • How Can We Improve? • Tips to Reduce Human Error • Digitize & Reduce Manual Work • Capture More Data • Apply High Performance Techniques • Get Data to More People • Q&A Today’s Agenda:
- 8. People Are Human People Make Mistakes Because They Can • Most systems do not directly consider human error prevention as part of the design • Human error is complex • Accounts for nearly ¼ of all unplanned downtime • Costs manufacturers millions • Attention, memory, alertness, illness, stress, and fatigue all trigger GMP violations, hurting quality and wreaking havoc with compliance
- 9. The Blame Approach – Not Helpful Failure To Understand Human Error • Companies still frequently fail to substantively and correctly address human errors • Typical response is retraining • Leads to less trust • Management is less aware of system weaknesses • Requires systemic view
- 10. How Can We Improve? Evaluate Everything • Management Systems • Procedures • Interactions • Human Factors Engineering • Training • Immediate Supervision • Communication • Individual Performance
- 11. Tips to Reduce Human Error 1. Digitize & Reduce Manual Work; Connect Systems and Remove Data Solos 2. Capture More Data 3. Apply High Performance Techniques 4. Get Data to More People
- 12. 1. Digitize and Reduce Manual Work
- 13. Remove Silos of Data HMI / SCADA MES / Quality Maintenance Management ERP No Connectivity Between Systems
- 14. Connect Everything Together Touch Panels Databases PCs Mobile Devices PLCs LIMs MES, QMS & ERP Systems Web Services MQTT OPC UA, OPC DA, OPC Tunneller Cloud Services Your System Connection Hub
- 15. Reduce Manual Work Streamline Processes • Eliminate whiteboards and clipboards • Eliminate personnel transferring data from one system to another • Capture data automatically • Integrate with ERP, QMS, MES, or other business applications • Create heads-up displays • Leverage RFID, badges, and barcode scanning
- 16. 2. Capture More Data
- 17. Legacy HMI/SCADA System Architecture
- 19. Access to Real-Time Data / Application See and Control Your Process Anywhere • Most important aspect • On-premise, remote, over VPN • Plant floor, office, home, remote • Access on any device • PC, Panel PC, TV, smartphone, tablet, etc. • No installation • No restoring backups • No licensing
- 20. Implement an MQTT Architecture
- 22. Add Edge Computing Advantages of Edge • Poll data at the source • Poll at faster rates • Get access to more data • Efficiently provide data to infrastructure • Add computing at the source (machine learning) • More security • True scalability
- 24. Add New Sensors Opportunities with New Sensors • Capture more I/O data • Overlay onto existing network • Connect to infrastructure • Wireless technology • Cost effective • No PLCs • No running conduit or power • Plug and play • Leverages MQTT
- 25. Example: Add Sensors to Detect Downtime Reason Eliminate Manual Downtime Entry • Accurately capture downtime event (start time and end time) • Get to root cause faster • Eliminate operators entering downtime manually • Entering wrong times or duration • Selecting incorrect reason • Operators will gain more context and gain more confidence • Focus on getting production running again
- 26. POLL What best describes your plant’s GMP maturity level?
- 27. 3. Apply High Performance Techniques
- 28. High Performance Focus Making the Best Possible Tool for the Operator • Turn data into information • Draw attention to the most important information • Add more context • Reduce reaction time
- 29. High Performance Focus Example: Analog vs. Digital Watches
- 30. High Performance Focus Example: Blood Pressure Reading
- 32. 4. Get Data to More People
- 33. Leverage Modern Browsers Access Anywhere • Leverage HTML5 & CSS3 • High level of security • Run anywhere • No plugins, native • Modern browsers (Chrome, Firefox, Safari, Edge) • Phones & tablets (iOS, Android) • Harness power of mobile device • Send secure web links • Familiar experience (Google Drive, Microsoft Office 365, AWS, etc.)
- 34. Enhance Security Modern Cyber Security Protocols & Infrastructure • Tried and true standards • HTTPS / TLS • Role and zone-based security • Auditing • Centralize identity management • Industry leading encryption protocols • SAML, OpenID Connect • Integration with 2FA systems • Extra layer, verify identity of users • Use existing corporate credentials • Supported by IT
- 35. Cost Savings with Connected Devices & Sensors BEYOND COMPLIANCE ● Human error causes nearly 1/4 of all unplanned downtime in manufacturing -> expensive ● The fewer touches, the better ○ workers displaced by automated data capture can be reassigned to higher value-added activities ● Sensors & devices less expensive to add than you think ○ many affordable alternatives ● Centralized reporting enables fact-based, on-the-spot decision-making and analysis
- 37. Resources White Papers & Surveys Webinars & Videos Product & Partner Info Solution Consultation Learn more at SafetyChain.com Follow Us for product updates, industry updates, & thought leadership: SafetyChain Software @safetychain @safetychain BEYOND COMPLIANCE