Top Plant 2012: Pfizer Global Supply

12/17/2012


By focusing on reliability-based maintenance concepts and workflow processes, equipment downtime is now less than 2%. Because of optimization efforts that started in 2008, PM activities have been reduced by 43% with savings of $3.9 million. Even with reduced PM activities, the plant has seen an increase in equipment uptime and availability. Given this focus, the maintenance department has been able to support greater than 90% equipment utilization within the APl plant and a 25% increase in volume in the DP plant.

Part of the reason the maintenance organization at the Kalamazoo plant has been so efficient can be attributed to cross-training. “A few years ago, we not only added a multiskill technician classification, but also focused on technician cross-training,” said Mark Callahan, senior manager, reliability engineering. “As an example, machine repairmen are trained to lock-out/tag-out the electrical side to disconnect motors in order to do a pump repair or replacement without having to pull in an electrician.

It’s actually working out very well,” Callahan said. “This has made us much more efficient in getting work orders completed in a timely manner and getting production back up and running.”

Automation diversity

The automated cartoner shows is integrated with other pieces of equipment associated with the Pfizer plant. Courtesy: Pfizer Global SupplyDiverse plant operations require diverse automation solutions. Multiple DCSs control the batch processes in the API plant. “We’re trying to reduce our DCS footprint,” said Thomas Andrews, senior manager, process automation. “Our batching system was installed prior to the ISA S88 standards. As we phase in the new DCS platform, we will focus more on an S88 implementation. We’re moving to a more flexible, agile batch solution, smaller phases, and more control at the lower levels.”

The S88 standards establish a consistent set of batch control standards and terminology to define the physical model, procedures, and recipes. The standard is intended to upgrade the controls to incorporate a contemporary batch control philosophy.

DP plant operations typically rely on PLCs with HMI and SCADA interfaces. “We use PLCs in the packaging areas and with robotics,” Andrews said. “We also have a lot of check-weighing systems. There’s a large amount of integration between the various pieces of equipment associated with the DP plant.”

Andrews manages a team of 17 automation engineers. “We’re managing some 95,000 to 100,000 I/O,” said Andrews. “The diversity of engineers required for a site like this is from one end of the spectrum to the other. From understanding instrumentation, process control, the processes, DCSs, HMIs, SCADAs, and the interface issues that are encountered, to the drug product technologies, filling, freeze-dry, inspection, the robotics for handling materials and running extremely fast lines, it really takes a lot of talent. And I’m fortunate to have been involved in assembling this team of engineers and putting that diversity together. We have packaging engineers, chemical engineers, and teams that know electrical, mechanical, and computer systems. It brings such a diversity of solutions to the table, it really is great.”

Improving safety

Pfizer’s Kalamazoo plant takes safety seriously. From 2011 to 2012, the plant cut the number of lost-time accidents in half, from six to three. The number of OSHA recordable incidents was reduced by nearly 30% during the same period.



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Improving flowmeter calibration; Selecting flowmeters for natural gas; Case study: Streamlining assembly systems using PC-based control; CLPM: Improving process efficiency, throughput
Putting COPS into context; Designing medium-voltage electrical systems; Planning and designing resilient, efficient data centers; The nine steps of designing generator fuel systems
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me