DCS Implementation Project Management

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This client, a leading manufacturer in the vaccines industry, required the supervision of the implementation of a Decentralized Control System (DCS) which pilots the production of a bulk manufacturer.

To begin tackling this challenge, we provided a complete functional analysis and optimization of our client’s industrial processes. This allowed us to define the resources and plannings required to develop a specific work strategy and methodology deployment process. With this, we determined the required software and automation design that needed to be produced within the given time-frame and budget.
Aside from external processes, internal infrastructure changes had to be made by coaching the engineering team and training the users to ensure successful implementation of new technologies and processes. By performing a deep analysis to effectively select thorough training programs, our focus is dependent on the successes of each individual involved in the developing process.

To meet the goals set out by our client, multiple solutions were implemented in order to create a coherent, integrated project solution:

  • DCS Implementation and Management
  • Integration with Downstream PLC Equipment
  • Commissioning and Start-up Follow-up
  • Clean Utilities (Purified Water; Water for Injection; Pure Steam) – Chemical Distribution – Mobile Vessels – Media Buffer and Transfer
  • Tuning Recipe Parameters
  • Management Changes

Implementation of the DCS enabled a new computerized control system to increase reliability while simultaneously reducing installation costs and enabling management of the control processes. The DCS is an optimal addition to this project as it is attractive for high value industries which involve safe and secure critical processes and compatible integration with downstream PLC equipment. Determining optimal tuning recipe parameters allowed us to design a unique combination of model parameters specific to our client’s applications.

Upon integrating our solution parameters, follow-up procedures in which we closely monitored the implementation of our proposed solutions indicated that that we succeeded in establishing a new DCS for our client. The installation of this new bulk manufacturing facility, coupled with the latest technology, allowed us to reach ASTM E2500 compliancy. Since this qualification practice was applied effectively, this approach resulted in saving both time and money while improving quality and safety.