Project Lifecycle for modification of manufacturing unit at Darlington Site

(Automation & Control Aspects)

Project Specifications :
Objective

: To Install a new tube filling and packaging unit in the manufacturing site without affecting
the ongoing production and safety constraints of the site so as to start manufacturing of
the new ointment to treat skin lesions.

Scope of Work

: Commissioning of tube filling and packaging unit in the existing facility

Budget

: 1.5 million (Maximum)

Time Frame

: 18 months
Report By :
Nishant Kumar Bakshi
Control Engineer
Front Line Pharma (Darlington Unit)

Process Diagrams
Process Flow :
Filling Unit

Preparation Unit

Packaging Unit

Dispatch

Our scope of work

Filling Unit (Proposed Model) :

Inflow of the
prepared ointment

Storage Tank

Weighing
Unit

Packaging
Unit

Bottling
Unit

Packaging Unit (Proposed Model) :

Bottling Unit
(gives the bottled product)

Sticker Containing
Composition and Bar
Code attached

Manufacturing Date
printed on attached sticker

Dispatch

Collector (to make set

of 10 bottles)

Wrapping
(Set of 10 wrapped together)

Suggested Process Description for filling unit

Suggested Process Description for Packaging unit

Our requirements
Individual Programmable Logic Controllers for each Unit with option of adding additional memory space. Also Remote input
and output panels should have double number of spare ports for future modification.

Use of same type of sensors and other equipments which are being used in other units of the manufacturing facility for ease
of procurement and inventory building.
Control System design should be such that it involves minimum operator intervention and maximum safety interlocks.
Control System Developed should have system monitoring capabilities (compare with ideal parameters with acceptable
tolerance level) and signal conditioning (self healing) abilities.
System should be easily integrated into current networking system of the existing (for level-3 automation)
Software Platform being used should be user friendly and should have life span of at least next 10 years.
Vendor should be easily approachable and should provide fault diagnostic on-site and Remote access Support.
At least 2 set of spares of each components should be provided for instant rectification of future faults.
On-site training for the employees who will be responsible for the operation and maintenance of these units.
Warranty of at least 2 years on the equipments must be provided by the vendor.

Vendor Selection and negotiations Aspects

Tasks Involved to Achieve the objective and planned time scale

Team strategy during erection phase

Final testing and documentation

Success Measuring Parameters