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Process Definition Management: Using ISA-88 and BatchML as a basis for Process Definitions and Recipe Normalization Paul Wlodarczyk and Mike Power WBF European Conference  11-13 November 2008
Business Imperative: Top Three Life Science Innovation Goals for 2012  ,[object Object],[object Object],[object Object],Survey respondents estimated 19% growth in spending on technology to support R&D in 2012;  this is slightly higher among branded and generics with estimated growth of 23%.  Mid-market Life Sciences companies also plan for more aggressive growth than their larger counterparts, they plan to increase their spending by nearly 30%. Source: AMR Research 2007 Life Sciences Survey Product Demand Supply
Product Life Cycle Process Definition Pilot Scale Early Development Late Development Project Management LIMS / SDMS QMS / CAPA Lab Scale Electronic Lab Notebooks Users Project Operations Scientists Chemists Biologists Pharmacists Engineers Technicians Operators Support Analytical Quality  MES ERP PLM Development Management Tech Transfer Clinical I Clinical II Clinical III Commercial Experiments Process Unit Procedures Commercial Scale Source: Mike Power, BearingPoint Product Demand Supply
Business Processes Impacting Time-to-Market: Early Stage Product and Process Innovation  Knowledge of  Future   Manufacturing  Environment ,[object Object],[object Object],Manage Process Knowledge Creation Knowledge  of Chemistry, Microbiology, Physics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],common information models Manage Process Knowledge Discovery Early Stage Product and Process Development: Lab to Bench Scale Pilot Source: Alison Smith, AMR Research Rapid Iterations Product Demand Supply
Business Processes Impacting Time-to-Market:  Late Stage Process Development  through Ramp to Commercial Manufacturing Foundation of preliminary process knowledge Experience in  Existing Manufacturing  Environment ,[object Object],[object Object],[object Object],[object Object],[object Object],Pilot to Scale Up for Commercial Production Continuous Improvements / Refinements within Design Space 12 – 36 mos. common information models Manage Process Knowledge Sharing Manage Process Knowledge Retention Manage Applying Process Knowledge Opportunity! Source: Alison Smith, AMR Research Product Demand Supply
“ Master Data”:  Coordination Points for Manufacturing include both Product and Process  Opportunity to use  ISA-88 recipe as the common information model for process definitions? Supply Demand Product  Design/Formulation Marketing Collateral Service Docs Data Sync E-Commerce Order Acquisition & Management Supply Chain Planning (mBOM, Routing) Sourcing & Procurement Product Package Design/ Label Claims Recipe Management Detailed Routing Bill of Equipment Bill of Process Bill of Compliance/ CoA Bill of Test Asset Maintenance Bill of Materials Process Specifications Process Engineering Maintenance Plans SOPs Asset Performance Management Opportunity to use  ISA-88 recipe as the common information model for process definitions? Opportunity to use  ISA-88 recipe as the common information model for process definitions? common information models
ISA-88 Operations Ice Cream Recipe Example The Blend Ingredients Operation  -  eight phases associated with blending ingredients. Note there is no rule on running only one phase at a time. In fact, it is very common for  multiple phases to be running simultaneously. Recipe represented in an industry standard ISA-88 SFC (sequential function chart)
A Solution for Faster Time to Market ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Development  Process Library Execution Systems Operator Instructions Submission Ready Components Contract Manufacturing Structured Data Sources Common Steps & Actions Common Steps & Actions Commercial  Process Library
Key Use Cases in  Process Definition Management  ,[object Object],[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
Create Reusable Manufacturing Actions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
Author Process Definitions (“Recipes”) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
Document Process Parameters ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
Technology Transfer ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
Process Knowledge Management ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
What is the Recipe for  Addressing these Issues? ,[object Object],[object Object],[object Object],[object Object],[object Object]
Solution:  Process Definition Editor ,[object Object],[object Object],[object Object],[object Object],Create  Reusable Manufacturing   Actions Author  Process Definitions Document  Process Parameters Transfer Technology Manage Knowledge
What is ISA-88 (“S88”)? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
What is BatchML? ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
The Process Definition Editor BatchML storage of recipes and recipe building blocks ISA-88 Editor for visual editing and navigation of Process Definitions Drawing palettes for ISA-88 shapes and reusable components Double-click on shapes to drill down, add process parameters
Product Life Cycle Process Definition Pilot Scale Early Development Late Development Project Management LIMS / SDMS QMS / CAPA Lab Scale Electronic Lab Notebooks Users Project Operations Scientists Chemists Biologists Pharmacists Engineers Technicians Operators Support Analytical Quality  MES ERP PLM Development Management Tech Transfer Clinical I Clinical II Clinical III Commercial Experiments Process Unit Procedures Commercial Scale Source: Mike Power, BearingPoint Process definition tools facilitate early process development 1 Process definitions refined, tech transfer at every point of scale 2 4 Tech transfer improved through machine-readable BatchML Process definitions transformed into ISA-88 control recipes in MES or Batch Control System 5 Manufacturing knowledge transferred to development through library of reusable process actions 6 ISA-88 recipes used for Description of Manufacturing Process & Process Controls (section 3.2.S.2.2) of CTD. 3
Proce s s Definition Editor ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Process Definition Management Using ISA-88 and BatchML Standards

  • 1. Process Definition Management: Using ISA-88 and BatchML as a basis for Process Definitions and Recipe Normalization Paul Wlodarczyk and Mike Power WBF European Conference 11-13 November 2008
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  • 3. Product Life Cycle Process Definition Pilot Scale Early Development Late Development Project Management LIMS / SDMS QMS / CAPA Lab Scale Electronic Lab Notebooks Users Project Operations Scientists Chemists Biologists Pharmacists Engineers Technicians Operators Support Analytical Quality MES ERP PLM Development Management Tech Transfer Clinical I Clinical II Clinical III Commercial Experiments Process Unit Procedures Commercial Scale Source: Mike Power, BearingPoint Product Demand Supply
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  • 6. “ Master Data”: Coordination Points for Manufacturing include both Product and Process Opportunity to use ISA-88 recipe as the common information model for process definitions? Supply Demand Product Design/Formulation Marketing Collateral Service Docs Data Sync E-Commerce Order Acquisition & Management Supply Chain Planning (mBOM, Routing) Sourcing & Procurement Product Package Design/ Label Claims Recipe Management Detailed Routing Bill of Equipment Bill of Process Bill of Compliance/ CoA Bill of Test Asset Maintenance Bill of Materials Process Specifications Process Engineering Maintenance Plans SOPs Asset Performance Management Opportunity to use ISA-88 recipe as the common information model for process definitions? Opportunity to use ISA-88 recipe as the common information model for process definitions? common information models
  • 7. ISA-88 Operations Ice Cream Recipe Example The Blend Ingredients Operation - eight phases associated with blending ingredients. Note there is no rule on running only one phase at a time. In fact, it is very common for multiple phases to be running simultaneously. Recipe represented in an industry standard ISA-88 SFC (sequential function chart)
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  • 19. The Process Definition Editor BatchML storage of recipes and recipe building blocks ISA-88 Editor for visual editing and navigation of Process Definitions Drawing palettes for ISA-88 shapes and reusable components Double-click on shapes to drill down, add process parameters
  • 20. Product Life Cycle Process Definition Pilot Scale Early Development Late Development Project Management LIMS / SDMS QMS / CAPA Lab Scale Electronic Lab Notebooks Users Project Operations Scientists Chemists Biologists Pharmacists Engineers Technicians Operators Support Analytical Quality MES ERP PLM Development Management Tech Transfer Clinical I Clinical II Clinical III Commercial Experiments Process Unit Procedures Commercial Scale Source: Mike Power, BearingPoint Process definition tools facilitate early process development 1 Process definitions refined, tech transfer at every point of scale 2 4 Tech transfer improved through machine-readable BatchML Process definitions transformed into ISA-88 control recipes in MES or Batch Control System 5 Manufacturing knowledge transferred to development through library of reusable process actions 6 ISA-88 recipes used for Description of Manufacturing Process & Process Controls (section 3.2.S.2.2) of CTD. 3
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