Emerson has expanded its DeltaV™ Real-Time Scheduling (RTS) software to include quality control (QC) laboratory scheduling for life sciences manufacturing.
The new capability extends real-time scheduling beyond manufacturing operations to help QC laboratories coordinate testing activities with changing production conditions. By automating scheduling rules and taking account of available resources, the software is designed to help laboratories reduce bottlenecks, improve resource utilisation and return test results more quickly.
For life sciences manufacturers, closer integration between manufacturing and QC laboratory activities can also support faster and more reliable batch release.
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Real-time scheduling for quality control laboratories
Quality control laboratories play an important role in life sciences manufacturing, but managing laboratory workloads can become increasingly complex as production operations scale.
Samples can arrive from multiple points across a manufacturing process, with laboratories required to carry out a range of analytical tests. At the same time, schedulers need to consider equipment availability, technician capacity, test requirements, incoming samples and changing production priorities.
This can make laboratory scheduling difficult to manage using manual systems such as whiteboards and spreadsheets. Laboratory information management systems (LIMS) may provide important information about samples and testing, but coordinating the overall laboratory workload and responding to changing production requirements can still present a challenge.
Emerson’s enhanced DeltaV RTS software is designed to address this scheduling challenge by connecting QC laboratory activities with real-time manufacturing conditions.
Synchronising QC testing with production
The new QC lab scheduling capability provides scheduling functionality directly within DeltaV RTS, allowing laboratory activities to be coordinated with manufacturing operations.
The system can schedule testing according to production requirements, helping ensure that testing is carried out at the appropriate time and using the appropriate equipment.
This includes both production-dependent testing and final product testing, allowing QC scheduling to reflect the relationship between laboratory analysis and the manufacturing process.
Integration with real-time laboratory information management systems can also automate alignment between laboratory schedules, sample availability and changing priorities.
This is intended to reduce the need for laboratory personnel to manually update schedules as production conditions change.
Automated and resource-aware QC scheduling
A key feature of the enhanced software is its ability to automate complex QC laboratory scheduling rules.
Laboratory schedulers can configure rules according to the requirements of their operation, taking into account factors such as equipment availability, sample workloads and testing priorities.
The software can also support advanced scheduling strategies such as analytical test run sample batching.
By grouping appropriate samples for testing, laboratories can make more effective use of analytical equipment while reducing potential bottlenecks in the testing workflow.
The ability to configure scheduling rules also provides flexibility when laboratory requirements change, including when manufacturers introduce new products.
Reducing QC laboratory bottlenecks
For life sciences manufacturers, delays in QC testing can have consequences beyond the laboratory itself.
Manufacturing may be unable to progress to the next stage of a process until required test results are available, while finished batches may require QC approval before they can be released.
By coordinating laboratory scheduling with production conditions, DeltaV RTS is designed to help laboratories return results in line with manufacturing requirements.
Kristel Biehler, vice president of life sciences for Emerson’s process systems and solutions business, said:
“Well-run QC labs are a keystone of ensuring quality and meeting delivery commitments. By driving efficiency, QC teams ensure samples are tested with results returned promptly, enabling manufacturing to proceed without delays and quality teams to promptly determine product disposition so therapies can reach patients on time,” said Kristel Biehler, vice president of life sciences for Emerson’s process systems and solutions business. “QC scheduling in DeltaV RTS software is a simple and effective tool providing automated, real-time scheduling to integrate the lab with the shop floor to make the most effective use of resources and eliminate bottlenecks.”
The integration of production and laboratory scheduling is intended to give QC teams greater visibility of changing requirements while reducing the amount of manual scheduling work.
Supporting faster batch release
The expanded DeltaV RTS functionality is designed to help life sciences manufacturers improve the flow of information between manufacturing and QC operations.
By ensuring that testing is scheduled according to production requirements and that laboratory schedules reflect sample availability and changing priorities, manufacturers can potentially reduce delays between production, testing and batch disposition.
For batch-based manufacturing, this can contribute to more predictable release processes and help manufacturers deliver products according to planned schedules.
The flexible configuration of scheduling rules also allows QC teams to adapt the system as testing requirements evolve. This can be particularly relevant when introducing new products or changing manufacturing processes.
Ultimately, Emerson says the new functionality can reduce manual QC laboratory scheduling effort while improving the on-time delivery of test results and supporting faster, more reliable batch release.
Integrated manufacturing and QC operations
The extension of DeltaV RTS into QC laboratory scheduling reflects the increasing integration of production and laboratory operations within life sciences manufacturing.
Rather than treating laboratory testing as a separate activity that takes place after production, real-time scheduling allows QC requirements to be incorporated into the wider manufacturing schedule.
For manufacturers managing complex testing workloads, multiple production priorities and constrained laboratory resources, this provides a way to coordinate testing more closely with the demands of the production environment.
Emerson’s expanded DeltaV RTS software therefore combines manufacturing scheduling with QC laboratory scheduling to help life sciences manufacturers improve resource utilisation, reduce bottlenecks and maintain a more responsive testing operation.
To learn more about the latest DeltaV RTS software capabilities for QC lab scheduling and flexible manufacturing operations, visit www.Emerson.com/deltav-rts.
Emerson Automation Solutions
- 0870 240 1978
- uksales@emerson.com
- Meridian East, Meridian Business Park, Leicester, Leicestershire LE19 1UX GB
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