Process automation is the use of automation technologies to allow process operations to be performed more efficiently and/or safely. Grantek’s process automation experience encompasses the food and beverage, pharmaceutical manufacturing, and consumer packaged goods industries.
By leveraging over three decades of experience and industry knowledge, we can help design an innovative solution to meet your company’s unique process automation needs. For example, if your facility has processes in place but your production line needs to be improved via automation and integration with other enterprise systems, that’s where Grantek excels. Grantek can also help with new equipment installs and connecting to the ERP.
When a new process automation opportunity is presented, Grantek works closely with our clients to understand both the existing process systems, and the project objectives. This allows us to create a detailed functional description document that outlines the new process automation solution proposed by Grantek. The functional description document will typically include: a control system architecture, detailed operational sequences, and examples of the user interface screens that will be used by the operators. Completing a thorough review and revision process with the client and other stakeholders will result in an approved functional description document that will form Grantek’s design basis for the project. At all stages throughout this analysis phase, we work with our clients to ensure that Grantek has a full understanding of their requirements.
Our Grantek Project Managers will assist in defining your project scope, developing the automation solution, deploying the strategy/solution. Our Project Managers will use the Grantek Project Management Methodology (PMM), which was developed from our 30 years of experience for both regulated and non-regulated industries such as Pharma (GAMP), Food & Bev & CPG, to ensure that your project is completed on schedule.
When the project gets underway, typical project flow consists of the following, software development and programming followed by, setting up simulation environments so we can run the new software independently of the machines,which is then followed by testing and optimization, before we perform the Factory Acceptance Test (FAT) if required, then finally the installing of the new system onsite and ensuring proper function, performing the formal Site Acceptance Testing (SAT).
Grantek has experience designing automation solutions for batching systems, continuous processes, dry material processing, and clean in place (CIP) systems. We also have extensive experience working within the food, brewing, pharmaceutical, consumer goods, wastewater, and dairy processing industries. We can implement Historian systems to store process data for regulatory compliance and future analysis. We can also design the reporting systems and tools that will allow our clients to understand and act on the process data they are collecting.
When your current process automation platform has become obsolete and is no longer supported, Grantek can help to develop and implement a migration plan that will allow you to transition to a modern control platform with minimal interruption to your production schedule. We will make use of scheduled downtime or maintenance periods to test the new control platform in preparation for the final migration. To minimize risk, we will always maintain to ability to revert back to the old control system at any time. In cases where no scheduled downtime it available for testing, we will design a phased approach to migration that will involve multiple smaller migration steps that can be accomplished without creating unacceptable risk to your production schedule.
The advantages of using Grantek for your automation integration are our extensive experience, our detailed knowledge of a wide range of automation technologies, and our deep understanding and knowledge of manufacturing processes and requirements.
Another major advantage of working with Grantek to design and implement your process automation project is our ability to perform integration at all levels of the GAMP-5 model: your process control system can be integrated with your ERP system, allowing manufacturing data to become a usable input for reporting and planning throughout your enterprise. This allows better process control, improved quality control, waste reduction, increases in efficiency and in many cases, overall cost reduction.