Historian, InTouch and iDAS enable efficient production of diabetes product

As a key maker of blood glucose monitoring systems for home and hospital use, LifeScan is dedicated to improving the quality of life for people with diabetes with its OneTouch brand products. LifeScan is a Johnson & Johnson company.

LifeScan Scotland was created in 2001 when Johnson & Johnson acquired the UK assets of Inverness Medical Ltd, a medical device company established in Inverness in 1995 to design and manufacture glucose test strips, and design electronic meters for the global diabetes market. Over 1,300 people are employed at the Inverness facility, which is regarded as a centre of excellence for those working in the field of diabetes.

With a focus on future development, LifeScan is committed to "creating a world without limits for people with diabetes" and to realise that vision relies on outstanding R&D professionals. The company's main product range includes the popular OneTouch brand of blood glucose monitoring systems, which is marketed globally. The company has also developed diabetes management software, control solutions and lancing devices and, in addition, produces the specialist test strips that work with many of the meters in the OneTouch brand line.

Key challenges .....

A mix of equipment supports the manufacturing plant at Inverness, including heating, ventilation and air conditioning systems, boilers, chilled water, compressed air, vacuum, steam generation, high voltage switch rooms, and condition monitoring units.

The major challenge facing LifeScan was that its legacy BMS (building management system), PLCs (programmable logic controllers), and controls all featured closed or proprietary protocols. There were many SCADA (supervisory control and data acquisition) and BMS front ends and very limited information on them available. Few companies could support the range of systems at the Inverness site.

The solution to be implemented also had to be designed to ensure open systems connectivity, and compliance with the Federal Drug Administration (FDA) 21 CFR Part 11 rule on electronic records and signatures, and ASM (Abnormal Situation Management - the process of developing valuable alarm/page design in the SCADA/process industry) principles. There needed to be much greater flexibility and control over software development.

The solution ....

The goals sought were open systems connectivity, FDA compliance, faster response times for breakdowns, condition based monitoring, more efficient use of site facilities and to become a leading site for Johnson & Johnson. To meet these needs, the Wonderware system using the products Historian, inTouch, and iDAS (industrial Data Acquisition Service) was installed by Caledonia Technologies, Westmont Systems and Solutions PT in the Facilities Department. The system architecture was developed by Solutions PT. Today, there are 20 people using the system - mainly shift and project engineers.

"Wonderware products and technology were chosen because of LifeScan Scotland's stringent requirements and because they met the required industry standards," says George Cameron, LifeScan Scotland Facilities Electrical/Controls Project Engineer. "They have so far replaced Mitsubishi MX SCADA systems, and we are also set to replace York Facilities Manager. The Wondwerware system is simple to use, with the training needed for implementation just onsite user awareness training."

Over the course of 2008, the system is utilising the Internet and company intranet for enhanced communication and control capabilities.

Benefits accruing ....

Initial results and benefits from the system were increased productivity, efficiency, asset utilisation, availability, quality and responsiveness.

"The system has evolved in two ways, through a strategy of replacing the legacy equipment, and also specifying new equipment with open protocols," says Cameron.

Additional benefits accruing to LifeScan from the system are better alarms, visualisation, trending and data availability, remote access, and SCADA alarms.

"With the help of the Wonderware system involving the Historian, InTouch and iDAS products, we have achieved tremendous connectivity on site," says Cameron. "We have been able to connect to PLCs, a BacNet BMS, several Atlas Copco compressors, Wago terminals and a Bacnet Carrier Comfort Network, to name but a few."

Future plans ....

Now, to better operate its facility, LifeSpan Scotland is utilising metrics gained from the system, such as characterising plant issues through analysis of trending and an improved alarm philosophy.

Further plans for implementing Wonderware systems include installing the ActiveFactory software and deployment of wireless InTouch stations. Additional benefits that LifeScan Scotland expects to gain from these implementations are faster response times for breakdowns, condition based monitoring, and the more efficient use of site utilities.

Because there is no data available as yet, it is too early to state in what ways the use of the Wonderware system has impacted the bottom line in regards to plant operating performance. Other benefits LifeScan expects to see with the system include energy efficiency and greater system availability.

Next, Cameron expects to involve management with the system and is looking for Inverness to become a leading site for Johnson & Johnson. That should not prove too difficult a task.