Management information systems (mis)

Production Data Historian Upgrade and Off-Site Test Facility Data Historian Projects

Configured AspenTech Historian Systems including redundant interfaces to production process, role-based security, 21CFR11-compliance-enabled monitoring, Batch analysis, SQL Server and Oracle instance configuration, and HP OpenView system monitoring.

• Configured the following interfaces between production process controllers and Data Historian Systems:
  • AspenTech CIM-IO to OPC interfaces to transfer data between production OPC servers and the AspenTech InfoPlus.21 data historian.
  • Allen-Bradley RSLinx OPC server interfaces to Allen-Bradley ConhtrolLogix and PLC process controls through ControlLogix Gateways.
  • Kepware OPC server interfaces to Yokogawa Ethernet and serial data recorders. Yokogawa serial recorder data was collected through an EtherLite terminal server.
  • Kepware OPC server interfaces to Modicon devices through a MEB-TCP bridge.
  • OPCConnect @aGlance Client/OPC Server interfaces to FlowStream MES.
  • Oracle OLE DB Client interface to High-Availability Oracle Server.
• Implemented Allen-Bradley ControlLogix/PLC based process simulation for testing of Batch system modeling using RSView, RSLogix 5000 and RSTestStand.

Performance and Information Management System (PIMS) Project

• Performed specification, design, documentation and implementation of PIMS system at customer site in Holland.
• Configured AspenTech software on two Windows 2000 Advanced Server machines to support redundant servers with fail over capability.
• Developed SQL scripts to automate configuration of complex history repository structure and role-based database security for AspenTech InfoPlus.21 real-time database.
• Implemented Siemens WinCC CIM-IO OPC interface to transfer process data between remote pilot plant and InfoPlus.21.
• Developed Functional Design Specification that included documentation of software installation and configuration procedures to enable customer to independently support PIMS system.
• Customer very pleased with documentation of installation/configuration and demonstrations of AspenTech software functionality.

Manufacturing Total Quality Management (TQM)

• TQM manufacturing system based on Aspen eBRS (electronic Batch Record System) product, developed for the pharmaceuticals industry to ensure batch quality by controlling critical operations in the production process. When a production order is released by electronic procedures, Aspen eBRS translates it into a set of operations, each of which must comply with FDA and GMP regulations.
• Performed AspenTech software configuration on multi-server production system, including configuration of barcode printer, barcode scanner, and remote terminal.
• Customer liaison, working with customer to assure correct design and implementation of production Aspen eBRS system components, coordinating modifications to Detailed Design Document with technical lead, as required. Developed excellent advisory relationship with customer.
• Developed/tested key components in the eBRS TQM system, including Real-Time Data, Hot Buttons, Pre-Weigh/Pre-Stage, Hopper Loading, Milling, Maintenance Batches, and the Database Interface. This component development included the creation of SQL Server 2000 views, stored procedures, and client-based queries. InfoPlus.21 real-time data was accessed via an OLE DB provider.
• Developed/implemented SQL Server link to AspenTech InfoPlus.21 real time database to achieve faster, more direct link between the eBRS system and InfoPlus.21 data.
• Implemented AspenTech CIM-IO for Bailey semAPI interface, providing data transfer between Bailey DCS and InfoPlus.21 database.
• Significant contributions to project planning, customer relations, and project management activities. These accomplishments contributed substantially to project success and customer satisfaction.

Production System Reporting

• Implemented wide array of complex Crystal Reports at customer site combining InfoPlus.21 real-time data and SQL Server 2000 relational data. Report features included drill-down, conditional formatting, multiple sections, sub-reports, complex formulas with control structures, parameter fields, and data from Crystal S QL Designer based SQL queries. Work included performance tuning and the implementation of logic to accommodate a wide range of customer data formats.
• Set up InfoPlus.21 real time database as linked server through OLE DB provider in SQL Server database. This enabled a production application to access both databases as a SQL Server ODBC data source.

Production System Migration

• Developed and verified Production Database design incorporating extensive customer input in a dynamic design environment.
• Created SQL Server version of customer legacy Production Database using Oracle SQL Scripts. Using “Reverse Engineering” feature in Visio, created ERD model and Table Report of SQL Server database. Developed Excel Workbooks to track data migration from legacy to new Production Database.
• Produced Detailed Design Document incorporating mock-ups of VB Operator screens, detailed descriptions of data flow, clear overview of work processes, and thorough documentation of database design and structure.
• Developed simple prototype to verify performance in areas of data input, storage, and processing environment.

Production System Design

• Designed custom data record structure to provide indexed storage of specification and process data, support lab data collection, impose InfoPlus.21 real time database limits on input parameters on Lab.21 manual input forms, and provide a means of seamlessly plotting data in Process Explorer. Lab.21 is a simple lab management package designed for customers not requiring a full-blown lab management system.
• Custom data record structure provided for efficient storage/retrieval of specification and process data, while reducing overall number of tags in IP.21 database. Lab.21 forms provided extensive functionality and automatic grading features important to the customer.
• Implemented raw and finished material grading schemes to provide automatic grading on Lab.21 forms.
• Developed VB application providing “drag and drop” viewing of InfoPlus.21 data to facilitate development

Advanced Process Control (APC) Post-Benefits Assessment

• Completed analysis of several key DMCplus and RTOpt systems. Calculated benefits produced byAspenTech systems by comparing process data collected both before and after the implementation of the AspenTech systems.
• Analysis methodologies, ground rules and assumptions were all arrived at in collaboration with client personnel. Client approved substantial benefits from these calculations.
• Provided AspenTech personnel with templates in Excel and PowerPoint to facilitate the calculation of benefits and the generation of benefits presentations. Benefits calculation templates were provided in Excel workbooks with links to PowerPoint templates.
• Customer approved substantial benefits from these calculations, resulting in $0.75M in contract bonus payments.

Manufacturing Execution System (MES)

• Developed/presented overview of 41 AspenTech software products comprising the MES Bundle for a customer.
• Prepared/presented demonstrations of 11 AspenTech software products to demonstrate functionality.
• Presented this overview to several groups during a Conference Room Pilot project. Customer was pleased and impressed with scope and thoroughness of presentations.
• Compiled electronic library of AspenTech materials providing customer with a concise overview of functionality and capabilities of the AspenTech software.
• These results were achieved over the first six weeks of employment with AspenTech.

Management Information System to ERP Interface

• The Management Information System (MIS) to PRISM (ERP System) interface transfers plant process consumption and production data to PRISM. This interface also transfers a PRISM Production Model for each product to be produced to the MIS system. The MIS system is comprised of an InfoPlus.21 real time database, CIM-IO Interfaces to transfer DCS or PLC process data to InfoPlus.21, and Batch.21 to record consumption and production characteristics, as well as subbatch durations.
• Built SQL script that loads Batch.21 Address Records into InfoPlus.21 database, based on Excel/CSV worksheet input. This facilitates the building of these records that map the location of Batch.21 values to be sent to PRISM.
• Developed Excel/VBA application, utilizing the Batch.21 Object Model, Batch.21 Application Interface, and BCU Application Interface, to automate the process of creating Characteristics and Tags in Batch.21.