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FactoryTalk Batch Performance Analytics

Your Golden Batch is within reach
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FactoryTalk Batch Performance Analytics

Achieving the Golden Batch

Setting up a batch in many facilities is often still a manual process, from measuring and adding the raw materials, to taking samples to ensuring a batch meets the desired results. At each step along the way, there is an opportunity for errors to occur because the system is not automated.

FactoryTalk Batch Performance Analytics is a new, purpose-built software application that is designed to provide comprehensive operational insights into batch system execution. Accelerate time to value by providing optimized process insights and enable improved productivity through data-driven decision-making. Batch manufacturing within the Life Sciences, Chemical and Consumer Packaged Goods industries will benefit from real-time alarming and analysis. Alert operators to batch process deviations, reducing variability by allowing for process corrections during batch execution. FactoryTalk Batch Performance Analytics delivers multi-level batch KPI insights with capabilities to compare single batch KPIs against a “Golden Batch” and track critical parameter deviations.

Life Sciences

The Life Sciences Industry is tasked to keep up with demand while maintaining quality and meeting regulatory requirements. Each batch must meet quality and safety standards. Are you meeting the Golden Batch standard every time? 

89.9%

Class 1 & 2 recalls are associated with manufacturing or product quality issues
 

Source FDA Drugs Recall Statistics

1,279

avg. FDA recalls/year mostly associated with manufacturing or product quality issues

Source FDA Drug Recall Statistics

80%

Batch failures due to contamination, operator error, equipment failure, failure to meet specs.

Source Biotech Facilities Average a Batch Failure Every 40.6 Weeks - BioProcess International

Introducing FactoryTalk Batch Performance Analytics

FactoryTalk Batch Performance Analytics helps consistently produce batches with set specifications, quickly identifying contributing factors in production variability and helping to improve regulatory compliance by automating data collection, analysis, and reporting of continued process verification. 

Does your Life Sciences process struggle with:

  • Keeping track of all the variables involved in complex formulations?
  • Getting feedback on manufacturing efficiency from siloed systems?
  • Tracking and reporting on quality assurance and regulatory affairs

FactoryTalk Batch Performance Analytics helps you:

  • Unlock the Golden Batch
  • Improve compliance through automated continuous process verification (CPV)
  • Streamline the manufacturing life cycle
Life Sciences by the Numbers
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Life Sciences by the Numbers

FactoryTalk Batch performance optimization at a glance.

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Golden Batch Manufacturing: A Golden Opportunity
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ARTICLE
Golden Batch Manufacturing: A Golden Opportunity

Today we want to explore the mechanics of manufacturing and when to know if it's right for your organization to implement Golden Batch manufacturing.

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Unlocking the Golden Batch

Define multi-level KPIs (for critical production steps and for the overall batch) for example quality, yield, throughout and cycle time.

  • Tie KPIs to PP/CPP and COAs
  • Collect historical data
  • Configure KPIs/Set the Golden Batch
  • Drill down to analyze single KPIs
  • Compare batches across sites
  • Compare current batch KPI to the Golden Batch KPI (for example quality and cycle time)
  • Receive alerts and adjust process parameters

Consumer Packaged Goods

Is Your Data Working With or Against You?

The CPG industry is faced with rapidly changing consumer expectations which is resulting in added operational complexity, margin compression and the need for advanced process visibility and control.

Process Development

  • Lack of formal, defined, multi-variable analytically-driven Golden Batch settings results in inconsistent quality
  • Lack of formal process adherence documentation
  • Lack of real-time deviation alerting and notifications

Manufacturing Operations

  • Rework due to inconsistent batches increasing material, energy, labor costs
  • Reliance on personnel to operate highly complex processes that cannot be fully automated introduces variability
  • Lack of real-time monitoring of process variability makes it difficult to achieve the Golden Batch for each run

QA and Regulatory Affairs

  • Increased risk of a recall due toinconsistent batch quality
  • High quality control costs due to time-consuming quality control quarantines and manual root cause analysis
  • Manual recordkeeping is inconsistent and error-prone

Tackle Batch Production Challenges with FactoryTalk Batch Performance Analytics for CPG

FactoryTalk Batch Performance Analytics helps consistently produce batches with specific specifications, quickly identifying contributing factors in production variability and help improve regulatory compliance by automating data collection, analysis and reporting of continued process verification. With FactoryTalk Batch Performance Analytics for CPG, you accelerate time to value with optimized process insights and improved productivity through data-driven decision-making.

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Aggregate & Contextualize Data

  • Collect data from disparate sources
  • Contextualize batch data  
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Setup KPIs and Alerts

  • Select KPIs, configure spec limits and weightage
  • Compare batch KPIs and against a Golden Batch
  • Set alerts/notifications to be sent to select users   
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Review Insights & Take Action

  • Review performance by site, plant, process cell, recipe, batch ID or time range
  • Drill down and analyze root causes of deviations
  • Use insights to improve process performance

Unlocking the Golden Batch with FactoryTalk Batch Performance Analytics for CPG

Improve business performance and outcomes through better process understanding

Reduce cost by leveraging real-time, multi-variable insights to optimize consistency and quality – regardless of raw material supplier, operator or processing location

Increase capacity by applying advanced analytics to reduce rework and improve cycle time

Free up limited labor resources by using pre-built application content, full lifecycle application support and simplified, error-proof processes that increase rigor, compliance and documentation

Enable Smart Manufacturing by adopting a robust scalable batch data infrastructure to enable predictive, prescriptive analytics

Manufacturing Execution Systems: A More Flexible Production Process is Possible

More responsive.

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10% Improved
yield and reduced losses

More informed.

Outline in blue of a magnifying glass

12% Improved
first-pass quality

More efficient.

Green outline of a production line with boxes on a conveyor

18% Reduced
production costs

Chemical

The chemical industry must increase operational efficiency, maintain consistent product quality, while ensuring costs hold steady and consumer demands are met. The challenge is visibility into processes to ensure efficient production.

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Market variability and pressure

Before the pandemic, nearly 50% of the top 100 chemical companies made changes to their product portfolio (McKinsey)

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Productivity and fixed-asset utilization

From 2011 to 2020 the quantities of production-related waste managed by the chemical manufacturing sector increased by 79% (EPA)

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Workforce effectiveness 

30% of skilled labor force is over 50 and expected to retire in the next 15 years (US Chamber of Commerce)

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Environmental, Social, and Governance (ESG)

 Including fuel and feedstock use, the chemical industries account for about 30% of the total energy consumed in the manufacturing sector (EIA)

FactoryTalk Batch Performance Analytics is a solution that helps you consistently produce batches within set specifications; the “Golden Batch”. Identify contributing factors in production variability and helps to improve regulatory compliance by automating data collection, analysis, and reporting of continued process verification.

Chemical Industry by the Numbers
Person in protective gear looking at stats collected at a chemical tank.
Infographic
Chemical Industry by the Numbers

FactoryTalk Batch performance optimization at a glance.

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Expected outcomes

computer-network-data

Accelerated growth through digital transformation

Unified operations platform
Manufacturing operations management
Batch performance analytics

chemical-optimization

Production optimization

Unified process and power control
Advanced analytics
Asset performance management

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Workforce enablement

Digital work instructions
AR/VR Connected worker

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Sustainable operations

WAGES management
Decarbonization of operations
Advanced continuous emissions monitoring

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