Control Associates will work with you to understand your manufacturing business goals, identify opportunities, develop a business case, and take a phased approach to implementation that is focused on ROI. We have the expertise to maintain your manufacturing operations systems in a secure, current, and optimized state to extract maximum value from your investment.
Control Associates can help you with everything from performing a business case analysis and developing requirements, to the design and implementation of an MES solution focused on delivering quantifiable benefits. Our solution can help you reduce human errors, improve compliance, eliminate labor intensive paper processes, and integrate data from various manufacturing systems.
Control Associates can implement a solution that leverages real-time data from your manufacturing systems allowing you to visualize your facility’s constraints, debottleneck the process, optimize your production schedule, adjust production schedules, perform dynamic maintenance planning, and understand the implications of any change in the manufacturing process. The model itself produces an optimal scheduling overview and capacity analysis. Ask us to see an example.
We are the experts when it comes to supporting your MES investment. Control Associates has the experience and expertise to assess the health of your system, optimize performance, and maintain your system in a compliant, cyber-secure, and supportable state. Control Associates offers an array of services and can tailor a plan to fit your needs and maximize the return on your MES investment. With decades of experience, no one else has this level of understanding and experience.
Optimize your operations and achieve your manufacturing goals. Our experts have the industry knowledge and experience to integrate your disparate data sources and enable data driven decisions. We can implement a scalable digital transformation strategy to integrate data from your OT systems—automation, operations management, laboratory results, & maintenance management—with your IT systems to create a common data management solution. Role-based visualization, analysis tools and reporting capabilities put the right information, at the right time, in front of the right decision makers.
It takes weeks or months to release a vaccine batch to the FDA for review. This big pharma customer previously had a complex batch record consisting of over 1,200 pages and taking over 30 days to complete. Every page had multiple opportunities for human error including incorrect entries, miscalculations, and executing steps out of order. Administrative controls as well as rigorous and time-consuming batch record reviews were required at the end of production to ensure product quality.
By implementing an electronic batch record in MES, this pharma manufacturer practically eliminated opportunities for error—enabling more predictable batch release cycle times, and ultimately reducing finished goods inventory.
With Cell/Gene Therapy, the treatment must be provided ‘vein to vein’ in a limited period of time—with the same rigorous controls as any other biologic. This manufacturer, not unlike others in this industry, also had additional process challenges to accommodate cell count variations in the starting material. In addition, this customer’s autologous process requires maintaining strict chain of identity across the supply chain with no room for error.
In Cell/Gene Therapy, the uniqueness of each batch requires it to be adjusted for every patient’s starting material. That’s where MES comes in: MES maintains control over a complex manual process; MES automatically tracks materials usage to an individual patient lot and maintains identity of the lot; and MES recipes help accommodate varied growth timelines for varying starting material.
Here’s the big deal: When you’re doing 5,000 production orders per year, saving 2 hours per order translates into 10,000 hours saved.
