Produce manufacture devices for control and regulation of technological processes
Posted by Anelis Aurand-Araos. Change control is a systematic approach used in many industries to manage all changes made to a product or process. This is particularly important in the pharmaceutical industry, specifically as it applies to pharmaceutical manufacturing where the complexity of the tasks to be performed during manufacturing, packaging and analytical release testing require detailed documentation of each task. Any changes in how those tasks are performed or managed need to be illustrated and justified through a change control.VIDEO ON THE TOPIC: What is PROCESS VALIDATION? What does PROCESS VALIDATION mean? PROCESS VALIDATION meaning
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- Process control
- What to expect from a career as a process technician
- Production and Process Controls
- For Production and Process Controls
- Webinar Q&A: Qualification of PAT Based Control Strategies for Batch & Continuous Manufacturing
- Advanced process control improves refinery, chemical plant operations
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OEMs servicing the healthcare and medical sector are feeling the squeeze as new technologies introduce as many new challenges as they provide opportunities and solutions. In a recent McKinsey Report manufacturing was found to be one of the sectors where automation can most easily be introduced. There are compelling reasons for OEMs to capitalise on the accuracy, efficiency, connected communication and agility that automation can bring. OEMs of medical devices are experiencing increasing challenges in terms of price and margin pressure, speed to market expectations, increased product and manufacturing complexity and more stringent regulatory compliance.
But, in other ways, it is a perfect opportunity for those who are positioned correctly to take advantage. So, how has automation helped cause this situation?
And how can medical OEMs position themselves to benefit from it? Other areas of innovation include robotic-assisted surgery, next generation smart inhalers that can track use and the ability to produce personalised products in small batches for specific patient requirements. Automation and machine learning are set to radically improve the supply chain for the healthcare sector. And data from devices collected during use can be continuously looped back to the manufacturer — for automatic ordering, performance feedback and even AI-initiated product improvements.
For OEMs, this data-connected supply chain will inevitably cause a shift from using many EMS suppliers to partnering with a select few. Inevitably, it will be those who are already intelligently automating and using smart technology to track and control production that will benefit. Stewart Gadd , Technical Director, Chemigraphic. The Internet of Things IoT is located at the point where physical objects with embedded electronics, software, sensors and network connectivity can automatically collect and exchange data with each other.
For electrical manufacturing, this means smart machines that can accurately capture real-time data as they communicate with each other and the products they process. This not only increases productivity, but it also identifies any inefficiency, increases quality consistency and avoids errors. Many electronic components used in surface mount technologies are — to the naked eye — identical. Control processes can be automated to avoid this. In relation to PCB, for example, each printed circuit board is given an individual barcode that enables manufacturing machines to access its production data.
Enterprise Resource Planning ERP systems will only allow the movement of components and materials between each stage of the manufacturing process once the necessary criteria are fulfilled.
The ERP allocates a unique serial number per product which is automatically placed on it to avoid any possibility of duplication, lack of serialisation or inconsistency. All surface mount stock is managed by a fully automated kitting and storage system that avoids the risk and cost of human error. In addition, RFID-enabled processing equipment tracks the movement of materials through the factory.
Every operator, and operation performed, is tracked and measured against estimated figures and then monitored on site-wide dashboards. This means that we have the fully archived traceability of process necessary for regulatory compliance, and also live management data which is critical to driving truly effective improvement.
The rate at which OEMs can get a new product to market is determined often by the time taken to gain regulatory approval. Such approval requires the collection of vast amounts of data through every stage of the product lifecycle. The IoT provides a pathway for the efficient production of increasingly complex products, while capturing and analysing data flows to assist with regulatory compliance and process improvement.
Advanced sensor technologies are increasingly enabling robots to take on tasks, like cutting gemstones, that had previously been reserved for highly-skilled craftspeople.
The role of automation is switching from high-speed and high-volume production applications to agile systems that can adjust on the fly, switching seamlessly between product types without the need to stop the line. Many emerging production technologies, from computerized-numerical-control CNC cutting to 3-D printing, bypass the need for tool changes, making it possible to produce batches of one. Medical device manufacturers must remain competitive by responding quickly to changes in patient treatments.
Customisation — and increasingly personalisation — of patient-specific devices will require high quality, high mix production that is perfectly suited to machine learning and automation. Of course, in the medical sector, it is critical that this automated production is vertically integrated so that corporate processes cannot be avoided: quality processes may demand that a device requires additional verification steps before the production process can continue.
The implementation of automation will, as a result, always be tempered throughout the medical device production process by compliance requirements and the need for quality control. And, this is just one way that automation will only ever be as effective as the skill, knowledge and experience of those who use it. This is something that our team at Chemigraphic has always firmly believed.
Read about how we recently supported the market introduction of Elekta Unity , a ground-breaking cancer treatment technology. Linkedin Youtube. Automation transforms the manufacture of electronic medical devices by Chemigraphic Aug 28, Blog. Automation, manufacturing and the medical sector In a recent McKinsey Report manufacturing was found to be one of the sectors where automation can most easily be introduced. There is intense pressure to produce and distribute medical products within ever-decreasing timeframes.
Simultaneously, the products are increasingly complex and regulatory requirements are more stringent and labyrinthine than in the past. The trend toward personalisation and miniaturisation of medical products simply compounds these challenges further.
Source The chronic staff shortages affecting paramedics could be greatly alleviated by driverless ambulances for low-level risk call-outs. Drones are already helping deliver essential medical supplies to remote parts of Rwanda.
Police are deploying sophisticated algorithms to predict where crime is most likely to occur — these Minority Report-style systems may be used for preventative medical treatment. The biochip market is estimated to be worth around USD17 billion by Source A new area of bioelectronic medicine is emerging, thanks to the miniaturisation of electronics — tiny devices implanted in the body may help treat arthritis, diabetes and asthma by influencing electric signals in nerve pathways.
Automation and the healthcare supply chain Automation and machine learning are set to radically improve the supply chain for the healthcare sector. Source And data from devices collected during use can be continuously looped back to the manufacturer — for automatic ordering, performance feedback and even AI-initiated product improvements.
From applying conformal coatings to protect circuitry and components in hazardous environments , to exclusive JUKI-automated kitting processes in our surface mount lines, we use smart, data driven techniques to not only increase the speed of production but also to eliminate errors and inconsistencies.
Stewart Gadd , Technical Director, Chemigraphic Eliminating error and delivering flawless performance The Internet of Things IoT is located at the point where physical objects with embedded electronics, software, sensors and network connectivity can automatically collect and exchange data with each other.
Automation is key to us — but, for us automation is about more than highly technical machinery. Automation is about using the tools and information we have around us to implement the best and most consistent methods of delivering the best results for us and our customers. Miniaturisation and personalisation Advanced sensor technologies are increasingly enabling robots to take on tasks, like cutting gemstones, that had previously been reserved for highly-skilled craftspeople. The most successful EMS operations are those which combine the mass delivery and rigidity of automation with the intelligence and flexibility of those programming the machines.
What to expect from a career as a process technician
Skip to main content. Process control is a statistical and engineering discipline that deals with the design and mechanisms for maintaining the output of a specific process within a desired range. These activities are involved in ensuring a process is predictable, stable, and consistently operating at the target level of performance with only normal variation.
D one of the more salient requirements of the regulation. In fact, the FDA has frequently focused their efforts on production and process controls during their friendly visits. Similar to design control, the requirements for production and process controls are substantial, so it is not possible, nor could Dr. D lend credence to the material by attempting to cover the requirements in just a single edition of Devine Guidance DG.
Production and Process Controls
Instrumentation and control engineering ICE is a branch of engineering that studies the measurement and control of process variables , and the design and implementation of systems that incorporate them. Process variables include pressure , temperature , humidity , flow , pH , force and speed. ICE combines two branches of engineering. Instrumentation engineering is the science of the measurement and control of process variables within a production or manufacturing area. Control engineers are responsible for the research, design, and development of control devices and systems, typically in manufacturing facilities and process plants. Control methods employ sensors to measure the output variable of the device and provide feedback to the controller so that it can make corrections toward desired performance. Automatic control manages a device without the need of human inputs for correction, such as cruise control for regulating a car's speed.
For Production and Process Controls
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Drug manufacturing is the process of industrial-scale synthesis of pharmaceutical drugs by by weight at a precise rate, and are often selected to minimize the flowrate variability that is caused by change of fill level and material bulk density. Once viral filtration is complete, sterility of the bulk drug substance is critical and single-use options for cooling can expedite the freezing process. What is Bulk drug? A bulk drug is a chemical substance that is represented and used as compounding, manufacturing, processing, or packaging of a drug, it becomes an active ingredient or a finished dosage form of the drug.
Webinar Q&A: Qualification of PAT Based Control Strategies for Batch & Continuous Manufacturing
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Advanced process control improves refinery, chemical plant operations
The economics of national operating companies are vastly different from international downstream organizations. Yet all are seeking ways to increase production margins, improve safety performance, and maximize equipment and plant reliability. Feedstocks and energy are the major costs items, so downstream companies must view the entire supply chain to optimize feedstock usage while shopping for the best value without compromising quality. Likewise, downstream companies strive to lower energy consumption and minimize waste, such as octane giveaway in transportation fuels. Automation and optimization strategies focus on how to schedule operations to produce high-demand transportation fuels, and petrochemical- and chemical-based products, while improving yields and conserving energy. Especially in petrochemical and chemical manufacturing, being a cost leader is an advantageous position, and cutting costs requires limiting process disturbances and downtime.
OEMs servicing the healthcare and medical sector are feeling the squeeze as new technologies introduce as many new challenges as they provide opportunities and solutions. In a recent McKinsey Report manufacturing was found to be one of the sectors where automation can most easily be introduced. There are compelling reasons for OEMs to capitalise on the accuracy, efficiency, connected communication and agility that automation can bring.
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We caught up with Paula Kearney, head of our BSc in Process Technology programme, to gain an insight into what a career in the biopharma process technology sector involves. Throughout her career, she has gained extensive experience in both drug substance and drug product manufacturing. She now designs and delivers bespoke training programmes for the industry and also lectures for Griffith College Dublin and TUD.
On- and in-line analysers are used in the framework of PAT Process Analytical Technology for controlling and monitoring unit operations in pharmaceutical operations for both batch and continuous manufacturing. The most basic requirement to utilize this technology in a GMP environment is that the instruments and their interfaces are commissioned and qualified before proceeding to the analytical method validation and productive use. A Process Analytical Technology system cannot be regarded as a stand-alone analytical lab instrument or as a piece of manufacturing equipment.
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