SYSTEMS AND METHODS FOR ADJUSTING PROCESS PARAMETERS IN A PHARMACEUTICAL PRODUCTION PROCESS
Methods and systems for process monitoring through data collection in a pharmaceutical production process include a data collector communicatively coupled to a plurality of input channels, each input channel connected to a monitoring point from which data is collected, the collected data providing a plurality of process parameter values for the pharmaceutical production process; a data storage structured to store collected data from the plurality of input channels; a data acquisition circuit structured to interpret the plurality of process parameter values from the collected data; a data analysis circuit structured to analyze the plurality of process parameter values to detect a process condition associated with the pharmaceutical production process; and a response circuit structured to adjust an operational process for the pharmaceutical production process in response to the detected process condition.
1 . A system for process monitoring through data collection in a pharmaceutical production process, the system comprising:
a data collector communicatively coupled to a plurality of input channels, each input channel connected to a monitoring point from which data is collected, the collected data providing a plurality of process parameter values for the pharmaceutical production process;
a data storage structured to store collected data from the plurality of input channels;
a data acquisition circuit structured to interpret the plurality of process parameter values from the collected data;
a data analysis circuit structured to analyze the plurality of process parameter values to detect a process condition associated with the pharmaceutical production process; and
a response circuit structured to adjust an operational process for the pharmaceutical production process in response to the detected process condition.
2 . The system of claim 1 , wherein the operational process is a rate of reaction in the pharmaceutical production process.
3 . The system of claim 1 , wherein the operational process is a parameter of operation at least one of a mixer, an agitator, a variable speed motor, a fan, a bearing, a shaft, a rotor, a stator, a gear, a rotating component, a pump, an inflow, an outflow, a pressure reactor, a catalytic reactor, a thermic heating unit, or a chemical reactor.
4 . The system of claim 1 , wherein the data storage further stores a plurality of collector routes, wherein the plurality of collector routes each comprises a different data collection routine, wherein a selected collector route is switched from a first collector route to a second collector route based on the analysis of the plurality of process parameter values.
5 . The system of claim 4 , wherein the switched collector route is due to the data analysis circuit detecting a change in an operating stage of the pharmaceutical production process.
6 . The system of claim 1 , wherein the monitoring point provides a continuously monitored alarm having a pre-determined trigger condition, and the data analysis circuit detects the pre-determined trigger condition.
7 . The system of claim 1 , wherein the process condition is a failure condition or an off-nominal condition for a pharmaceutical production component, wherein the operational process is altered to decrease a safety risk.
8 . The system of claim 1 , wherein the operational process is altered to increase productivity of the pharmaceutical production process.
9 . The system of claim 1 , wherein data analysis circuit utilizes a neural network to analyze the plurality of process parameter values.
10 . The system of claim 9 , wherein the neural network is a probabilistic neural network to predict the process condition as a fault condition.
11 . The system of claim 9 , wherein the neural network is a convolutional neural network to make a recommendation based on the analysis of the plurality of process parameter values.
12 . The system of claim 9 , wherein the neural network is switched between a first neural network to a second neural network by an expert system.
13 . The system of claim 1 , wherein the data analysis circuit compares the plurality of process parameter values to a stored vibration fingerprint to detect the process condition.
14 . The system of claim 1 , wherein the data analysis circuit utilizes a noise pattern analysis to detect the process condition.
15 . A computer-implemented method for process monitoring through data collection in a pharmaceutical production process, the method comprising:
collecting data from a data collector communicatively coupled to a plurality of input channels, each input channel connected to a monitoring point from which data is collected, the collected data providing a plurality of process parameter values for the pharmaceutical production process;
interpreting the plurality of process parameter values from the collected data;
analyzing the plurality of process parameter values to detect a process condition associated with the pharmaceutical production process; and
adjusting an operational process for the pharmaceutical production process in response to the detected process condition.
16 . The method of claim 15 , wherein the operational process is a rate of reaction in the pharmaceutical production process.
17 . The method of claim 15 , further comprising storing a plurality of collector routes in a data storage, wherein the plurality of collector routes each comprises a different data collection routine, wherein the collector route is switched from a first collector route to a second collector route based on the analysis of the plurality of process parameter values.
18 . An apparatus for process monitoring through data collection in a pharmaceutical production process, the apparatus comprising:
a data collector component communicatively coupled to a plurality of input channels, each input channel connected to a monitoring point from which data is collected, the collected data providing a plurality of process parameter values for the pharmaceutical production process;
a data storage component structured to store collected data from the plurality of input channels;
a data acquisition component structured to interpret the plurality of process parameter values from the collected data;
a data analysis component structured to analyze the plurality of process parameter values to detect a process condition associated with the pharmaceutical production process; and
a response component structured to alter an operational process for the pharmaceutical production process in response to the detected process condition.
19 . The apparatus of claim 18 , wherein the operational process is a rate of reaction in the pharmaceutical production process.
20 . The apparatus of claim 18 , wherein the data storage component further stores a plurality of collector routes, wherein the plurality of collector routes each comprises a different data collection routine, wherein the collector route is switched from a first collector route to a second collector route based on the analysis of the plurality of process parameter values.