A major focus at all three meetings was to discuss the current adoption level of Process Analytical Technology (PAT) and advanced software solutions in the industry, as well as the expected impact of such technologies on future advancements in operations excellence.
In general, a recent industry-wide survey conducted by Tefen and Millipore Corporation indicated that more than 50 percent of the 100 industry-leading organizations who responded either have a PAT program in place or are planning to initiate such a program during 2005. The survey also revealed the three most valuable PAT features industry professionals seek to initiate are: real-time product release based on in-process testing, improved characterization of process variation leading to reduced regulatory scrutiny, and improved product quality assurance through proactive design for manufacturing. When surveying the expected time frame for such functionalities, about one-half answered they expect those solutions to be common in the industry in only four to ten years, while twenty to thirty percent estimated a much quicker adoption of one to three years.A key speaker at Genzyme's session, Glen Williams, general manager of Biogen-Idec's facility in the Research Triangle Park, NC, presented a session on process data management using a system that collects data from a variety of sources such as LIMS, DCS, document management, and manual entry. The system supports statistical process control (SPC) analysis, process monitoring, and raw materials evaluation. Combined with the use of a multivariate analysis tool, the facility is able to identify and highlight key causes of variation from batch to batch and works to eliminate them. The system implementation is a key step to adopting PAT at Biogen-Idec.
Genzyme's Manoj Menon, process engineering manager, provided a presentation on the use of process data statistical analysis for efficient scheduling of manufacturing operations. Through detailed data capture of production information in the filling area on average filling yields and lyophilizer load sizes, optimal campaign sizes were determined for various formulations to minimize lost lyophilizer capacity and scrapped product. Menon explained that without the ability to collect and present valuable data, this project would have been impossible to complete.
Lisa Miller, director of manufacturing, and Regina Grochowski, senior manager of compliance, Human Genome Sciences (HGS), offered a presentation at the west coast meeting summarizing HGS' implementation of a variety of advanced IT solutions. From CAPA to ERP, HGS put a number of critical systems in place. This effort required significant, dedicated IT and implementation resources, but because the company views technology as a priority, it was able to meet its ramp- up targets.
Peter Bland, senior manager at Global Change Control at Genentech, presented a company project that transitioned an object-oriented document model for batch records. Based on a company assessment, one of the causes for a slow new product introduction process was the difficulty in creating documents — people were spending a significant amount of time creating new documents from scratch, while numerous versions of documents for similar processes already existed, resulting in confusion on the part of the operators using the documentation. Through a Six-Sigma project, Genentech identified a potential 50 percent reduction in labor time invested in document creation by designing standard templates, or objects, that are reused to create process documentation. A key project requirement was that the developed object model could integrate nicely with a future manufacturing execution system (MES) solution, currently in the planning stages at Genentech.