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Predict How Automation Will Behave in the Future

Predict How Automation Will Behave in the Future

Our Real-Time Modeling System allows you to visualize your facility’s constraints, accommodate variability, maximize production, and understand the implications of any change in the manufacturing process.
 
By collecting data from across the organization, the system can consolidate, analyze, and present an accurate model of the entire process. The model then produces an optimal scheduling overview with debottlenecking and capacity analyses for process optimization.

Features of Our System

Create a Virtual Sandbox for Plant Experimentation
Our Real-Time Modeling System software is an environment that has the flexibility to model any facility, operation, or process. It uses one platform for both analysis and finite-scheduling utilizing discrete-event simulation.
Develop an Always Feasible Real-Time Schedule
Using a model created by the Real-Time Modeling System, real-time scheduling automatically schedules future operations based on operations rules by reconciling the real-time status of the manufacturing floor.
Determine the Current Bottleneck and Target Improvement
Utilizing plant data, run what-if analysis to detect bottlenecks that are impacting operational performance. Through iterative improvements and changes in process parameters, recognize significant refinements in throughput, and analyze impact on KPIs.
Track Facility Performance Metrics Based on Consolidated Corporate Data Sources
Create datasets from batch historians to be used in the modeling system. Using this data, calculate and manage performance metrics such as OEE scores or golden batches and update these metrics automatically to reflect the most up-to-date data.

Real-Time Modeling System Benefits

Design Validation
Validate process design prior to capital expenditure.

 

Bottleneck Detection
Establish a clear and accurate debottlenecking pathway.

 

Facility Flexibility
Future proof facilities for multiple products and higher titers.

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New Technologies
Understand the effects of new technology on your process. 

 

Utilities, Waste, & Labor
Generate highly detailed models of WFI, labor, gases, and other potential constraints.

 

Capacity & Cadence
Determine feasible facility capacity and cadence (including surge capacity).

Real-Time Scheduling Benefits

Schedule Adherence
Accurately monitor facility goals and personnel efficiency.

 

White Space Analysis
Easily view and plan maintenance activities without disrupting plant operations.

 

What-if Scenarios
Immediately see the impact of strategy changes on schedule and facility performance.

 

Automatic Schedule Updates
Reflect the current status of all recipes to the schedule through integrations framework and update the future schedule. 

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Peak Utility & Labor Requirements
Visualize peak demand for critical utilities, labor, or other potential constraints. 

 

Views for Functional Teams
Create and publish views for activities dedicated to different teams or operators.

 

Operator Allocation
Automatically assign operators to tasks based on capability matrix and availability.

Contact us to learn more about the products, services, and solutions that Caltrol provides to Cell & Gene Therapy organizations.