As is often the case in Pharmaceutical controls, a struggle exists to successfully integrate the recipe systems of the master control system with those of OEM skids. More often than not, this is one of the most difficult areas to homogenize within a given process. When you factor in that a given process line may have multiple skids from multiple vendors, the problem compounds itself even more. This may be a scenario that your facility has had, or is still struggling with.
Although there are an infinite number of ways to integrate the systems, one of the least difficult methods is that of "recipe matching". Recipe matching involves either "pushing" a given recipe down from the master control system or "pulling" a recipe up from the OEM skid and comparing the two electronically. When the recipes are compared, any differences can be either flagged as a mismatch or recorded as a process override depending on your needs and validation requirements. Since this comparison can be made multiple times during the process, it allows for initial preset matching as well as the recording of local field changes or in-process updates. A hidden benefit is that it allows your OEM equipment to run standalone, in a non-GMP manner, for maintenance and testing activities.
When applied in conjunction with a facilities electronic reporting system, recipe matching can be a great way to seamlessly integrate third party "islands of automation" into a centralized and cohesive control system. Strategies like this allow you, the end user, to leverage the most from your preferred vendors while maintaining ease of operation within your facility.
We have the expertise and experience to evaluate and apply these control methodologies as well as others to your new or existing control system. We welcome the opportunity to continue this discussion with you at your facility.