Streamlining legacy machine integration
Author : Giuseppe Menin, COPA-DATA
30 January 2024
Legacy machine integration is one of the biggest challenges during data integrity remedial plans. Here, Giuseppe Menin, Life Sciences & Process Industry Manager at automation software supplier COPA-DATA, explores how an advanced automation integration layer (AIL) introduced by COPA-DATA can support manufacturers on their journey to a more connected plant.
Driven by the complexity of integrating disparate machinery into digitalised workflows, COPA-DATA has created the Automation Integration Layer (AIL) for use in manufacturing operations, and has designed it to integrate legacy machines seamlessly into automated workflows. AIL uses a vertical data integration approach to incorporate the shop floor with IT infrastructure for a more efficient operation compliant with data regulations.
The central hub for enhanced connectivity
AIL functions as middleware, connecting existing machines and devices within pharmaceutical manufacturing operations. It offers several key functionalities to enable flexible and effective connection. It has wide connectivity, allowing it to be compatible with operational technology equipment (OT), including older automation controllers.
AIL also enables the contextualisation of key data by collecting critical process parameters (CPP) and providing aggregated data, such as minimum, maximum and average values at the end of batch phases.
The platform can also generate alarms to alert operators when parameters exceed predefined limits. AIL allows operators to access and view their collected data, as well as distributing it to other IT systems when needed for more connected processes.
Simpler connection and integration
Integrating legacy machinery into the AIL requires a case-by-case evaluation. Real-time data acquisition is typically straightforward, while collecting historical data may be more challenging due to variations between machines. However, COPA-DATA uses a modular approach with Smart Object components in its software platform, zenon, which allows for the creation of machine integration objects that can be reused for similar machines, streamlining the integration process.
AIL is based on the zenon software platform, enabling seamless integration with other automation platforms, including modular production with MTP, the well-established Werum PAS-X, and the zenon Historian 360 for comprehensive data storage and contextualised analytics.
By leveraging the functionalities of zenon, manufacturers can access various modules, such as historian, zenon logic for data aggregation and contextualisation, recipe management, alarm and audit trail acquisition, and communication interfaces like Werum PAS-X, SAP, and Aspentech, among others. This integration provides significant benefits for plant operations, as it reduces the implementation effort by utilising ready-to-use functions within a configurable manufacturing automation software platform.
Bridging data gaps
The AIL ensures data integrity compliance across all equipment and machinery, including legacy systems. It serves to bridge the data integrity gap in existing machines by employing an integration strategy tailored to each machine's capabilities. Factors such as the availability of an audit trail, user management capabilities, and the ability to acquire critical process parameters (CPPs) enrich the integration approach. By carefully evaluating these aspects, manufacturers determine the best integration approach to meet data integrity requirements and overcome any existing gaps.
In terms of product development and validation processes, AIL is a configurable software platform compliant with GAMP5 CAT.4 guidelines, minimising the need for extensive scripting and reducing the overall validation effort. Through the platform's standard features, manufacturers can rely on a widely-used product that simplifies product development and validation processes. This streamlined approach enhances efficiency and accelerates time-to-market for new products.
By implementing the AIL, manufacturers gain access to valuable data that can drive improvements in various aspects of manufacturing processes. The acquired data enables manufacturers to consider additional factors such as sustainability, efficiency, and waste management. With the ability to analyse and utilise data, manufacturers can optimise operations, enhance throughput, reduce waste and achieve overall process efficiency.
By adopting a vertical data integration approach, the AIL facilitates efficient operations, while ensuring compliance with data regulations. With COPA-DATA’s AIL, manufacturers can overcome the complexities associated with legacy machinery and work towards a smarter, more connected plant through data-driven decision-making and streamlined processes.
Find out more about how the Automation Integration Layer by zenon tackles some of the challenges involved with legacy machine integration here.
Contact Details and Archive...