How a Front-End Study Saved Nearly $1 Million for Our Client

“Blue Skies” analysis — an exhaustive exploration of every possible capability, solution and outcome.

About the company

  • Objective: Implement a multi-year strategy for Industry 4.0 enablement.
  • Industry: Pharmaceutical
  • Result: High Availability Architecture saving $905k
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The Background

Striving for Industry 4.0

The top global pharmaceutical company had ambitions for several digital transformation initiatives and engaged TQS to provide a multi-year strategy for Industry 4.0 enablement.

TQS analyzed the company’s existing infrastructure and capabilities — with the specific aim of drafting a standard process manufacturing data acquisition methodology and implementation strategy across 8 manufacturing sites

The Challenge

Lack of access to data

The biggest challenge was that the company was “data starved” — there was a lack of direct access to process manufacturing data by the data consumers. Instead, there were data silos, with certain data accessible by one group of the organization, but not the rest. As we know it, accessing the right data in a standardized format efficiently is key in any process manufacturing industry especially for pharmaceutical companies. As a result of this friction with the data collection and conversion process, the company was wasting a lot of time — leading to delays in strategic business decision making and the implementation of the new initiatives.
See an 80% cost savings in systems integration.
PI system eliminates the need to access unstructured data from multiple sources.
Empower client with 160 man-hours saved per month.

The Solution

Extensive Research to Probe Deep

The initial action was a front-end study, by way of a comprehensive review of the sites with regards to the availability and acquisition of process manufacturing data into a centralized data platform (to be used as a global data concentrator for all platforms requiring real-time data).

This was followed by an evaluation of the current data infrastructure which comprised of, Blue Skies” analysis - — an exhaustive exploration of every possible capability, solution and outcome.

Finally, the OSIsoft PI tag naming convention was proposed, critical element to align with other site data systems.

"We are very happy that TQS recommended and implemented a front-end study for us before we engaged with any extensive data infrastructure and integration changes. Not only did it save us valuable time and effort, it also saved us a lot of money. Recommendations put in place by TQS also simplified our data processes so that we can access our data more easily which allowed us to make more optimal busines decisions." Remarked Head of Operations, top global pharmaceutical company."

The Results

A Complete Set of Recommendations

A report was generated for each site with a complete set of recommendations including IIoT (industrial internet of things) deployment and maintaining operational excellence.

This report allowed a discussion in greater detail about what the client’s requirements were and what the best course of action was.

Following the recommendations provided to the sites, it was agreed to move ahead with a local OSI PI data historian per site in a full High Availability Architecture.

Below is a list of the data types captured into the OSI PI data historian and a list of the ongoing initiatives to use this data.

Process Data​
Alarm & Event Data​
Batch Context Data​
Audit Trail Data
IIoT Sensor Data

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