Chemical Manufacturing plants have two extreme scenarios. The continuous plants are heavily automated whereas the batch production plants have mostly manual work flows. For manual plants, Industry 4.0 would have huge impact if they adopt digital and paperless execution. For continuous plants, Industry 4.0 has huge opportunity to enable Digital Twins by integrating all the silo systems with a unified view.
Vegam team has pioneered the digital transformation of batch process plants handling material movements, production recipes & SOPs, varying levels of automation and associated complexities. In one of world’s largest adhesive plant or largest automotive paints plant, Vegam SFS is the nucleus of digital transformation. Vegam SFS was one of the first solutions in the world to operate a manual line using “predictive insights and prescriptive approaches”
Digital Twins are the future of manufacturing optimization and visualization. Demand for remote management of manufacturing has also fuelled the need for Digital Twins. Ability to simulate scenarios and visualize the implications is helping management aid in capital investments and strategic choices.
In continuous processes, digital twins are helping identify golden batch operating parameters, predictive maintenance, consistent yield etc, apart from visualisation and optimization capabilities. Vegam offers vDigiTwin platform wherein all the data related to production are unified, synced and structured. Relevant relations between data sources and systems is established so that the end-2-end flow of materials, operations and information is available with all the inter-relations & dependencies captured. Open APIs enable third party applications develop applications with access to structured data. Easy to develop Real-Time and Off-Line visualization views using a Drag & Drop interface supported by vDigiTwin.
Chemical manufacturing employs multiple resources shared among production lines. Resources like reactors, mixers, bottling and filling units have different capacities and rates of operation. Human capital available on a daily basis would also define the rate at which production can happen in these plants.
Vegam SFS, SFS Lite and vPromax are different solutions and modules addressing the challenges to visualize plant operations, performance and optimize the production in real-time. OEE calculations, down time measures, bottle neck resources analysis etc are tools to aid better planning and execution. Real-time KPIs and Dashboards with historical trends help in organizing effective daily morning meetings for better synergy among various operating teams. The solutions help in enhancing the overall health of the plant operations.
With the ability to seamlessly integrate across all technologies & systems of a complex chemical working environment, Vegam’s systems also help optimize production assets and their life and minimize spend.
Multiple applications and systems used by plants with extensive paper trails are error prone with very challenging synergy among teams. Dependency on multiple disjoint teams and associated impact on quality and yield is very high. Proactive and reactive remedies are very difficult as the scale of operation increases. Ability to implement continuous improvement approaches and assessing their impact is challenged.
Vegam SFS provides Digital Execution Solution whose modular architecture helps in unifying multiple applications and extending the solutions as and when needed. Vegam SFS allows for digital paperless operations with real time visibility of all aspects of production. KPIs and dashboards offer contextual drill down of data across operators, processes, equipment, inventory and quality results, covering multiple systems. Vegam SFS offers real-time alerts on deviations to SOPs or parameters, giving ability for plants to take reactive measures and avoid failures or process deviations.
The integrated data with secure trace logs offers 100% traceability of “Material, Man and Operations” involved to produce a batch of material.
Studying the process parameters that have resulted in the perfect batch and adopting the same on future batches is a very powerful approach to enhance quality and yield in chemical manufacturing. As the variables are many, it requires multi variant analysis. As many of the parameters have dynamic natures, a real time model developed using AI/ML methodologies can enhance the overall benefit.
Vegam Team brings expertise, skills and resources needed to work with the “Information repositories” and develop solutions that can generate data driven predictive triggers. Vegam team can help develop predictive models for Golden Batch production.
GMP expects strict SOP’s followed with regards to Asset maintenance and calibration. Preventive maintenance schedules, daily checklists and break down maintenance management are part of regulatory and compliance needs in production. Performing these task and recording the same is a large part of the operations at plants. Errors, discrepancies, delays can have serious implications to the business.
Vegam vMaint4.0, Vegam SFS & Vegam SFS Lite offer solutions and modules to support paperless management of all aspects involved in managing maintenance activities. Vegam addresses the core challenges in adopting off-line or paper based solutions by bringing in mobility and real-time capabilities. Integrated with IoT, Vegam supports advanced capabilities like “Predictive maintenance”, Artificial Intelligence & Machine Learning based alerts and triggers to operate the plants in a proactive mode.
Benefits of paper-less, IoT based maintenance include:
Batch / Recipe based manufacturing has complex material management, starting from planning, procurement, storage, prestaging and staging to supporting right quality & quantity at the right place & time. This covers Receipt (including audits for very critical material) & Quality hold, Sampling & Testing and Storage of Material. Efficient Material Management can help:
Current systems across small to large manufacturing setups are beset by paper trials and/or multiple complex systems. This makes it difficult to track and capture & display material data accurately and in real time to support production and compliance (audit trails for very critical material) requirements. Apart from production halts, inability to track material data in warehouses results in heavy raw material and finished product losses.
Vegam Solutions’ Vegam SFS and vWarehouse helps manufacturing plants track and capture material data accurately. This helps companies efficiently manage material movement, have real-time inventory data ready for seamless production and reduce material losses.