Case Study
GSK Maidenhead
Project:
GSK Maidenhead
Client: GlaxoSmithKline (GSK) Oral Care Manufacture (OCM) facility, located in Berkshire.
History: The GSK OCM facility had numerous quality-critical instruments that required replacement. These instruments were essential for controlling and monitoring the batching processes for the Koruma mixers and Colour Blending Units.
"The integration of modern, intelligent instruments has significantly improved our process control and monitoring capabilities, ensuring continued high-quality production at our facility."
- GSK Maidenhead OCM
Solution
Silchester Control Systems Ltd undertook the task of replacing the outdated instruments with modern, intelligent flowmeters, updated pressure transmitters, level transmitters, and flow switches. The new instruments were integrated into the existing control systems architecture. Key steps included:
- Connecting the new instruments directly to existing Profibus DP networks or via existing remote I/O modules.
- Reviewing and installing additional repeaters for six Profibus networks due to distance constraints.
- Implementing an Endress & Hauser FieldCare / Asset Monitoring system to facilitate diagnostics and calibration status data retrieval from the new instruments via a PC-based workstation.
Silchester Control Systems Ltd provided comprehensive project management and design services, including:
- Creating documentation in accordance with GAMP5 and GSK requirements.
- Defining the revised control system and network architecture.
- Supervising the mechanical installation of the instrumentation.
- Modifying existing control panel designs using AutoCAD.
- Supervising the instrumentation installation, control panel modifications, and network configuration.
- Updating P&IDs in accordance with GSK process tag revisions.
- Modifying software using STEP7 for six Siemens S7-300 / S7-400 PLCs to incorporate the new instrument configuration while maintaining legacy data and communications.
- Liaising with production to minimise downtime.
Validation was carried out in accordance with GAMP 5, GSK requirements, and SCS internal procedures, with design and validation documentation produced according to Computer System Validation guidelines.
Results
The upgrade resulted in:
- Enhanced performance and reliability of the batching processes.
- Improved diagnostics and calibration capabilities through the new intelligent instruments.
- Continued compliance with GAMP5 and GSK standards.
- Minimal production downtime during the upgrade process.
Silchester Control Systems
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