The site’s problem
The building manufactured vaccines with paper records: equipment preparation, washing, media and solutions, fermentation, purification. Everything had to move to electronic batch records.
The group already had a shared MES model, the core model, used on other sites. But it did not cover everything this building did. The question was simple to ask and long to settle: what do we reuse as it is, and what has to be designed for this building?
What we did
We reused the core model functions wherever they fitted. For operations specific to the building, we created Process Instructions, that is, the instructions the MES executes at the workstation. Each choice was made with the site and with the team responsible for the core model.
We were involved from requirements gathering through to post-go‑live support, including specifications, configuration and qualification. We were responsible for qualification. We connected the testers with quality assurance, drawing on our knowledge of the system and of validation expectations. The scope included exchanges with the ERP, the SCADA and the weighing systems.
Three Maelo consultants worked on this project. One for MES expertise and qualification. One for requirements gathering, specifications, configuration and testing. A third joined at go‑live for production support, problem analysis, corrections and user training.
What it delivered
The building went live with the MES on the planned date. Sixty users were trained.
For media preparation, around ten Process Instructions are enough to manage approximately seventy items. Post-go‑live support covered all production areas.
A similar need at your site?
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