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Press Release11 July 2021
How Ukraine’s pharma leader Farmak embraces digital transformation
World-renowned SIMATIC IT by Siemens has become the cornerstone of the company’s digital operations. Field-proven technology helps collect and process digital data consistently. Siemens Ukraine also provides training for staff and international certification.
So what are the key project innovations?
1. More flexible and independent operations
This is possible thanks to SIMATIC PCS7 distributed process control system. More automated and digitalized systems allow changing drug formulations and process flows on the go. An operator uses a control panel to quickly select a formulation and launch it into production while constantly controlling the production process. At the end, a production report is generated. All documents are digital, so is the operator’s signature, no paperwork involved.
Compared to the traditional equipment, such a compact and closed digital system has the following benefits:
- guaranteed repeatability of processes;
- less space for human error;
- possibility to monitor and analyze all deviations from the norm;
- improved effectiveness of pharmaceutical products;
- Text1020% reduction in production costs.
Step by step, all production processes at Farmak will soon be digitalized.
2. Continuous monitoring of drug preparation process
Fifteen advanced workstations monitor the process in real time. In essence, the digital system provides remote access to both the manufacturing systems and engineering infrastructure. The shop manager and foremen can connect to the operator’s monitoring panel to observe the production process together with him.
A sophisticated video surveillance system comprising 130 cameras constantly monitors all major process flows and logistics. The cameras are located in clean areas and along all supply routes for basic raw materials and formulation components.
Shop managers can see every production detail on the screen.If a process fails, it is carefully monitored and analyzed using video. The data is stored for six months and can be used to improve the production process.
3. Real-time process simulation
With SIMIT software, you can create a digital twin even before the process starts. This way, a technology can be tested in a virtual environment and improved before the equipment is installed. In earlier times, you had to shut down production to make improvements.
The simulation reduces time for commissioning and start-up by over 50%.In the future, Farmak employees will be able to use SIMIT technology to optimize and master new technological processes without stopping the manufacturing process.
4. Managing engineering systems
Engineering support is one of the key elements of the production process. It creates the necessary microclimate in the workspace by maintaining proper air exchange, temperature, and humidity.
DESIGO CC, a powerful platform by Siemens, which is a part of the SIMATIC PCS7 modular system, makes the whole process a breeze.Shop personnel can use DESIGO CC to monitor the condition of all utility systems and control microclimate directly from their workplaces. Clean areas have special digital panels displaying GMP (good manufacturing practice), microclimate parameters, particle content in the air, and changes in pressure. This is especially important when creating aseptic drugs for injections.
These parameters are strictly regulated; in case of any deviations light alarm on a special signal tower goes off immediately. Green light indicates that the process parameters are within the normal range; yellow light shows that there is a deviation; and red light is a signal of a critical situation. The latter case is also accompanied by a sound alarm. Employees know exactly what to do in such situations and they act according to special protocols.
5. Digital collection and recording of data
Paperless production. Farmak’s experience shows that you need to fill in 100,500 pages to produce one industrial batch. And Farmak produces 8,000 batches a year.Paper nowadays is gradually becoming a thing of the past.Time has come to collect and record information in a digital file containing all the necessary protocols, from laboratory tests and quality control of primary raw materials to information about all the stages and parameters recorded in the course of drug preparation.
Siemens experts have already helped Farmak to launch a pilot project featuring a digital file system. Based on it, a full-scale system can be rolled out in the future.
«Сіменс АГ» (Берлін і Мюнхен) - міжнародний технологічний концерн, який протягом більше 175 років є синонімом технічної досконалості, інновацій, якості і надійності і проявляє глобальний підхід до бізнесу. Компанія веде свою діяльність у багатьох країнах світу і спеціалізується в таких областях, як інтелектуальна інфраструктура для будівель і розподілені енергосистеми, автоматизація і цифровізация промислових галузей. Siemens об'єднує цифровий та фізичний світи заради створення додаткової цінності для суспільства та споживачів. Завдяки «Транспортним рішенням Siemens», провідному постачальнику інтелектуальних рішень для магістрального і міського транспорту, рухомого складу та залізничної автоматики, Siemens допомагає формувати світовий ринок пасажирських та вантажних послуг. Завдяки мажоритарній частці в публічній компанії Siemens Healthineers, Siemens також є провідним світовим постачальником медичних технологій та цифрових медичних послуг. Крім того, Siemens володіє міноритарним пакетом акцій Siemens Energy, світового лідера в галузі передачі та виробництва електроенергії, яка вийшла на фондову біржу 28 вересня 2020 року.
У 2020 фінансовому році, що завершився 30 вересня, оборот концерну склав 57,1 млрд. Євро, а чистий прибуток – 4,2 млрд. Євро. На кінець вересня 2020 року в Siemens працювало 293 тисяч співробітників по всьому світу. Дізнатися більше про компанію можна на сторінці: www.siemens.com і www.twitter.com/siemens_press
Contact
Marina Maslej
Siemens Ukraine
Yaroslavska str. 58
04071 Kiew,
Ukraine
04071 Kiew,
Ukraine
+380 68 538-2410