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Pharma API & Formulation Manufacturer

Engineering Information System

This is a global pharmaceutical company based in India, known for its role in the development, manufacturing, and marketing of a wide range of pharmaceutical products. The company has a diverse portfolio that includes generic and branded medications. It is known for its strong research and development capabilities, allowing it to innovate and expand its product offerings. They reported an annual turnover or revenue of approximately INR 25,500 crore (or around USD 3.5 billion)

Problem Statement

Engineering Information System for Plant

  • This client was looking for a smart Asset register to link with SAP PM module (for. E.g.: PUMP for one system has related Motors, Cables, PLC connections and interlocks with Datasheets, Maintenance plans, Inspection plans, IQ documents and Periodic Validation documents)
  • Centralized system to maintain and capture all plant documentation in intelligent manner
  • Streamline ongoing site changes and capture them on drawings and documents with detailed audit trails
  • Batch manufacturing change overs
  • Verify gravity slope lines for ZERO pockets as per standards and document it with validity
  • Link Assets to PFDs, P&IDs, Layouts, IQ, PQ and QMS system
  • Most challenging aspect of Asset Tag on different drawings and System. (E.g.: PUMP tag number on vendor supplied P&ID, on OEM datasheet, inside PLC, in SAP and in QMS are all different)

Our Solution

We customized COMOS to have following:

  • Detailed Plant Hierarchy w.r.t Process Break Down (PBS) and Plant Area Breakdown (ABS). This gave the flexibility as well as auto association of various Assets
  • Develop Location drawings (similar to REVIT’s floor plan) in COMOS to prepare intelligent Layout drawings
  • Multiple Tag numbering schemas for Single asset to auto-generate tag numbers for Project ID, QMS ID, SAP ID and even display them on Drawings and Documents as per User’s wish
  • Build COMOS WalkInside Model from AutoCAD plant 3D and linked to respective assets in COMOS to perform the following:
  • Visualize 3D model with Sensor Calibration plan – colour coded based on number months balance
  • IQ and PQ qualified / Unqualified Assets
  • CIP / SIP Flows on 3D Model for Operator Training
  • Simulation of Operation Logic on P&ID

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