optimizing global deployment of a pi system...

© Copyright 2015 OSIsoft, LLC

Carl Van Laer Presented by

Optimizing Global Deployment of a PI System Infrastructure with an Enterprise Agreement


This presentation is confidential, proprietary information of Johnson & Johnson

Optimizing Global Deployment of a PI System Infrastructure with an Enterprise Agreement

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• Janssen in a nutshell

• OSIsoft PI System deployments in the past

• SPIRIT – global deployments on NGI

• EA or no EA – that’s the question

• Benefits of new approach

• Future plans

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• OSIsoft PI Server deployments in the past




• Future plans

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Janssen in a nutshell

• During the last half-century, we have brought together a number of innovative pharmaceutical companies with one overarching goal: to address and solve some of the most important unmet medical needs of our time. Today, we are united under a common name — the Janssen Pharmaceutical Companies of Johnson & Johnson.

• Together, we share a vision of providing innovative solutions that bring value to people, healthcare professionals and health systems around the world. Driven by our commitment to patients, we deliver products and services that offer hope and a healthier life to people throughout the world.

• See also www.janssen.com

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http://www.jnj.com/

http://www.janssen.com/








• Future plans

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OSIsoft PI System deployments in the past

• We have had OSIsoft PI System for many years but in the past it was deployed:

– Site specific

– Plant specific

– Functionality implemented varied project by project

– Validation varied project by project

– Setup / usage / support varied project by project

=> No standardization, data difficult to share,...

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But then SPIRIT came

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Standardise across the Enterprise








• Future plans

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Regional instance is the new default

• TCO of regional instance is lower

– Need fewer IT specialists to support basic infrastructure

– Implementation cost is lower

• Install once – use many

• Validate once – use many

– 1 common support structure leveraging standard J&J IT procedures

• Regional OSIsoft PI System is deployed in DC on NGI

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NGI

• New Generation Infrastructure

– SDDC

• Reliability

• Extendibility

• Flexibility

• Fast delivery

• Lower cost

– 1st step to Cloud?

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Architecture

• 3 environments (regulated industries) – DE - Development – AE - Acceptance – PE - Production

• All virtual • Standard VM builds • No data loss • 24x7 availability • Combining VM high availability with OSIsoft high availability options • New:

– No AF collective – F5 load balancing – “Always on” – MS SQL Server high availability

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Architecture - PE

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Challenges

• Site maturity – change management process:

– Local QA Global QA

• Validation approach

• Tools used

– Local system responsibility shared responsibility

– Local support shared support

– Facts emotions (bad experiences in past)

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• Future plans

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The EA - licenses

• The EA was an enabler for the global deployments:

– Uniform license structure (no worries)

• No budget discussions for projects

• Leverage all functionality – no compromise

• Maximize data collection & usage

– Ability to set up 3 environments (DE, AE, PE) – all licenses included

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The EA – EPM - SPOC


– Enterprise Program Manager

• 1 point of contact speeds up things

• Provides insight and direct access into the OSIsoft processes and roadmap

• Is internal advocate and voice for J&J inside OSIsoft

• Provides a cohesive front to the many facets OSIsoft offer via monthly status reports, periodic reviews, and on an ad hoc basis

• Makes it easier to get issues resolved.

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The EA - monitoring

• Global support model

– mPI:

• Ensures higher availability of the PI System

• Reduces J&J staff for monitoring

• Allows J&J to focus on strategic initiatives over maintenance activities

• No need to set up our own monitoring systems

– Complements support structure

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The EA - CoE


– Support of CoE of OSIsoft in defining the new architecture, taking into account the (future) evolution of the OSIsoft products (AF Analytics)

– Support of CoE in using AF, PI Cloud Connect, PI Cloud Access to further standardize content & visualization and to extend data visibility to our suppliers/partners

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The EA - development

• Involvement in the development of new interfaces (e.g. MES) required to create fill visibility on all manufacturing data from lab to patient

• Involvement in the development of new intelligent connectors to standardize content and decrease implementation and validation costs

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The EA – that’s NO question

• Conclusion

– Would we have been able to realize our vision without EA?

– Extending the EA to other JSC and Consumer sites

– Extending the EA to MD?

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• Future plans

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Benefits – IT/Deployment

• Lower TCO

– Implementation & validation (50% of engineering cost)

– HLM (Less capital required for new deployment)

– SLM (Less servers to maintain)

• Faster deployment = faster realization of business value

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Benefits - Business

• Standard content and visualization tools used across the J&J enterprise (CON, JSC, MD) – create once, use many

• Data visibility across sites – lab to patient, including 3rd party manufacturing

• Sites are comparing apples with apples

• Enabling automated CPV across JSC

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Mobility

• PI System available via IT Standard JNJMOBILITY Network (Edge Client)

• Process and Energy Data visualized on iPads/ iPhones

• Data from any location with PI System can be visualized on wireless devices.

• PI Cloud Access! –Possibility of more freedom of data access from outside JNJ.

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PI Cloud Connect – Realizing Concepts • External manufacturer - AF Template and Elements to SPIRIT Global Standard and Integrated to JNJ

Global AF DB - Automatically visualized on SPIRIT Process Visualization Module • External Partner Team: SPIRIT, OSIsoft and External manufacturer. • Connecting with Global IT – Security Assessment on application approach, data integrity and alignment

with JNJ Global Standards.

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Global Content - Cross Sector Capability

Consumer

Pharma

MD&D

Regional PI Servers – Supporting Sites with NO

LOCAL INSTANCE

Global AF Server S88 Model – Interconnecting all PI System across all site and platforms – 11 Pharma Sites Connected

PI Cloud?

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Global AF & Energy Monitoring • First! Meter Templates – Standardized

Visualizing Usage • Now! Commenced definition of Content

Standards for Utility Equipment • Now! Visual template linked to Global AF • Same Approach – Any site/ anywhere

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Real life business benefits

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Business benefits:Improvement

(%)AIL MES

Historian &

AnalyticsERP

Faster Recipe Approval 40%

Reduce labor costs by centralized process visibility 10%

Reduce labor hours spent collecting production data and producing

reports50%

Proactive Operation 15%

Reduce production investigation time 50%

Reduce manual inputs and double checks 90%

Human Error reduction 50%

Reduce paper (logbooks & reports) 80%

Reduce labor costs by a centralized process data repository

(process validation, maintenance & calibration) 20%

Reduce labor costs spent in performing batch and product review 50%

Reduce process control system idle 25%

Improve Knowledge Management System 75%

Extend/Transfer Data Storage capabilities overcoming equipment

limitation80%

Data consistency across processes 75%

Contributing Systems








• Future plans

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Future plans

• Complete data collection:

– Complete PCS OSIsoft integration on (some) sites

– Deploy OSIsoft PI System to new sites in JSC, CON and MD

• When appropriate, regionalize existing local OSIsoft PI System (HLM, SLM) after (standard) risk assessment

• Extend collaboration with OSIsoft in product development (GUI, interfaces (intelligent connectors), MDB to EF, reporting,...)

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• Standardized content & visualization – data visibility across the whole supply chain

Solution(s) Results and Benefits

One source of truth for JSC

Business Challenges

A. Key process data not available across the enterprise

B. No standardized content, visualization

C. Need process improvement and CPV, PAT…

A. Strategic approach – full use of EA to standardize the landscape

B. Executing a roadmap to standardize and create data visibility from lab to patient

C. Standard ‘one’ PI System

“OSIsoft PI System is an Enterprise System that brings all operational, business, event, and real-time data together from multiple source systems, to make it readily available to all users across the enterprise anytime and anywhere!“

Kevin Crean, SPIRIT lead

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Carl Van Laer

[email protected]

IT Manager Manufacturing Systems

Janssen Pharmaceuticals

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Questions

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