CASE STUDY
Capabilities Demonstrated
The Client:
Pharmaceutical manufacturing company
- New equipment automation
- Remote FAT
- Plant automation simulator
- Batch-process automation
- Electrical design
- PLC programming
- DCS programming
- VFD installation / integration / configuration
- HMI software development
- Reporting software development
- Database configuration
Problem
Solution
SkyIO was a sub-contractor to a prime contractor for this project. The prime contractor delivered the overall skid-based manufacturing system. SkyIO provided the batch control system automation expertise.
Results/Outcomes
- Increased global market share for vaccine product
Project Overview
SkyIO focused on the control system aspects of the system, while the prime contractor delivered the overarching skid-based manufacturing system.
SkyIO performed the following:
- Hardware Design Specification (HDS) development.
- Software Design Specification (SDS) development.
- Control system Electrical & Instrumentation (E&I) design.
- Batch system programming.
- Validation of control system hardware and software.
- Remote startup support.
- Language translation functionality (customizable language tables provided to end customer; they provided the translation).
SkyIO provided control system expertise (design, definition, programming, guidance), while the customer provided process knowledge.
A hybrid DCS/PLC batch system was developed to assist operators in the manufacturing process for a repeatable and high-quality product. Recipes were used to facilitate the process of making the vaccine. The transfer and mixing of solutions was fully automated.
The customer led Factory Acceptance Testing (FAT). SkyIO was involved in assisting with test runs and executing the Software Verification Testing (SVT).
Software Developed
- Batch process automation
- Operator interface application (HMI)
- Custom Batch Reporting
- Plant automation simulator
Hardware Utilized / Integrated
- Siemens control hardware
- VFDs
- tanks
- valves
- pumps
- scales
- mixers
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