A MES/WDS (Manufacturing Execution System/Weighing & Dispensing System) web-based production management and weighing system controls fermentation plant at Lonza Biotec in the Czech Republic Lonza Biotec in the Czech Republic, one of the world‘s leading suppliers to the pharmaceutical, healthcare and life science industries, has invested in a multi-product manufacturing facility that increases the company’s fermentation capacities by 50%. The combined Production Management and Weighing System, for this facility is controlled by a web-based Pilot MES/WDS from Felten. The entire Lonza system was designed and implemented in just 6-months, using cost effective Pilot software modules that combine hardware from different suppliers into one homogeneous system. The system’s numerous interfaces and modular structure mean that it is fully open for future expansion, and has the potential for SAP connection in the near future. Lonza has more than 6400 employees worldwide and owns 23 production and R&D sites, including Lonza Biotec in the Czech Republic, which was founded in 1992. Lonza Biotec employs more than 350 people and specialises in the production of API intermediates and L-carnitin. Lonza’s investment in the new multi-product manufacturing facility was necessary to meet the increasing demands for microbiological products for pharmaceutical applications, and also human nutrition supplements. Key to the success of the overall project was Lonza’s requirement for a combined Production Management and Weighing System. When selecting the system platform, Lonza attached great importance to efficiency, scalability and the widest range of system capabilities. In addition the company wanted a system that would provide transparent process workflows and optimised processes to enable the maximum in cost saving, delivering a quick return on investment (ROI). Felten was able to satisfy all of Lonza’s requirements with its web-based Pilot [MES] Weighing and Dispensing System, and was awarded the order for the combined system. The web-based system convinced Lonza with a number of key features. First, with its upgradeability: the result of the modular structure of Pilot MES. Second, the ability for complete integration into the existing automation and system structure. Third, the system’s easy, quick and safe operability. Fourth, the Pilot system’s strict compliance with FDA and cGMP regulations. The Pilot MES Production Management System provides an integrated solution that connects business order processing from ERP systems with automation control systems. It provides a cost effective solution that meets all requirements; and reveals weak points as well as bottlenecks in production processes. As the software is implemented as a web portal, any business- relevant data and processes are made available company-wide. The operation is intuitively carried out, using a standard web browser with mobile clients (PDAs), which are connected to the Pilo® system via wireless LAN. The integrated Weighing and Dispensing System Pilot [WDS] installed at Lonza consists of the modules „Weighing“, „Discharging“ and „Washing“, and it guarantees the production process in the area of recipes. WDS, as well as MES, work independently from any special hardware, but interface with all available scales and terminals (e.g. Bizerba, Sartorius or Mettler Toledo). Weighing can be performed concurrently on as many weighing stations, as required. As all available scales are integrated into the supervisory Production Management System, the production orders are directly transformed into weighing orders, with simultaneous documentation of all process data. The use of barcode scanners to identify equipment and products enables easy and quick input. This consequently reduces input errors to a minimum. The weighing system conforms to the highest quality requirements. The system itself makes decisions and performs them as far as possible. Thanks to the basic Pilot structures, the weighing system operates with utmost reliability and high system availability. Process relevant data are stored redundantly, and have their own login security system that permits access only to authorised personnel. To guarantee a smooth production flow, Pilot [MES/WDS] performs comprehensive control and documentation tasks at Lonza. During the emptying, weighing and cleaning process, a permanent control of the respective batch recipe takes place with regard to the raw material used and its correct weight. Any interventions and alarms are recorded in an audit trail and documented in the weighing protocol. In integrated mode, the system is connected with the batch system, the distributed control system (DCS) for reports regarding raw material usage, and with an Oracle database for central storage and documentation of the weighing process. The required data and recipes, as well as the respective production steps, can also be handled in stand-alone mode. The final batch report is then stored in a special directory serving the DCS. At Lonza, DCS, batch automation and weighing are combined in one fully automated system. The weighing area receives its information via a direct interface from the DCS, which decides on the basis of the batch recipe and which material has to be weighed, filled and transferred to the fermentation reactor. Subsequently, WDS reports the actual quantity of material used back to the DCS. The weighing server is connected with the Oracle database, in which any data are finally stored and available for long term archiving. The user is guided through the production process by a series of dialogs via handheld PCs; these handheld units also communicate with the server online. Special dialogs ensure the safe combination of individual work steps, such as weighing, loading and cleaning. To further simplify the operation, the product and equipment identification is supported by barcode readers.
Modular MES system
