What is SCADA?

  • SCADA (Supervisory Control and Data Acquisition) is a system for centrally monitoring and controlling a wide range of equipment and systems. It accumulates and analyzes data while monitoring and controlling the data sent from various devices and sensors. It has a database as a device that connects the upper system (MES or ERP) with the production site, and has many benefits such as production equipment and data management and analysis, diagnostic information, power data, and understanding of operating status. Until now, it has been used in large facilities such as factories and power plants for real-time data collection and process control. In particular, in plants, supervisory control systems have been useful because they enable rapid response when failures or abnormalities occur.

Benefits of using SCADA

The use of Supervisory Control and Data Acquisition (SCADA) brings many benefits to the monitoring and control of large facilities and systems. The main advantages of using SCADA are:

  • Merit1

    It enables real-time data collection and process control, ensuring accuracy and consistency throughout the production run.

  • Merit2

    This enables rapid response in the event of a breakdown or abnormality, supporting efficient operation.

  • Merit3

    Data collection and recording is essential for regulatory compliance, and SCADA makes this easy.

On the other hand, without SCADA, it will be difficult to enjoy these functions and benefits. Real-time monitoring and control will be difficult, and responses to abnormalities may be slow. In addition, data collection and recording will be more time-consuming, which may make regulatory compliance more difficult. Furthermore, production efficiency and cost reduction may also be affected.

  • If you don't use SCADA

    Since data is stored independently in each device, real-time analysis and monitoring are difficult. Each device is operated independently via HMI.

  • When to use SCADA

    The data collected from each device is integrated and stored within the SCADA, enabling real-time process control.

Benefits of using SCADA in the pharmaceutical industry

SCADA also plays a very important role in the pharmaceutical industry. Pharmaceutical manufacturing processes must follow strict quality control and regulations. Utilizing SCADA allows for real-time monitoring and control, ensuring precision and consistency throughout the production process. Data collection and recording are also essential for strict compliance with regulations such as GMP, and SCADA makes this easy. There is an increasing need to promote digitalization and ensure data reliability to guarantee data integrity and safety. Linking with MES contributes to further productivity improvement.
Due to the revision of the GMP ministerial ordinance in Japan and the tightening of regulations by overseas inspection agencies, the use of SCADA as a countermeasure is increasing. However, the current situation in pharmaceutical manufacturing plants is that automation and digitization are still not advanced, and handwritten documents are still used. Although the authenticity is considered to be beyond doubt, there is a risk of tampering in reality, so electronic recording with emphasis on data integrity (guarantee of data completeness) and parametric release (assurance of safety of medical products) is required, and SCADA, which can accumulate all work history and data, is starting to be used as an information infrastructure in the field.

Products and services provided by IDEC Factory Solutions

We provide a total "SCADA product package" and "system construction" that is optimal for the pharmaceutical industry.

SCADA Product Package

  • IDEC Factory Solutions offers SIEMENS "SIMATIC SCADA SYSTEM (SIMATIC WinCC Audit)". Based on a scalable open system environment, SIMATIC SCADA vertically integrates data from production and MES/ERP levels to cloud solutions, providing solutions that can meet not only current challenges but also future challenges.

    We aggregate data acquired from various subsystems and build a unique database. Centralized management allows you to access the information you need at any time. In addition, data mining allows for efficient analysis of data and evaluation in a way that suits your purpose. This allows you to aim for greater operational efficiency.

    IDEC Factory Solutions has more than 20 years of experience as a system integration partner of Siemens Ltd. in Japan.

SIMATIC WinCC Audit (optional software)

  • SIEMENS offers optional software, SIMATIC WinCC Audit, for recording audit trails required for compliance with Part 11. In particular, the pharmaceutical industry needs to meet the user requirements for audit trails stipulated in the guidelines for compliance with GMP (Good Manufacturing Practice) and 21 CFR Part 11. SIEMENS offers its own system that is not only a necessary function for Part 11 compliance in the pharmaceutical industry, but also guarantees the integrity of the original records for customers.
    Part 11: A regulation issued by the FDA (Food and Drug Administration) in 1997 to allow the protection and storage of records and signatures in a paperless (electronic) manner. The contents of the regulation include "audit trail," "safety and data integrity," and "documentation."

What SIEMENS SCADA can do (Functions required for pharmaceutical industry equipment)

System construction (system integration)

IDEC Factory Solutions has specialized SCADA construction capabilities and advanced system integration technology, and provides optimal systems that meet customer needs and supports the realization of effective operation. When a system integrator builds a SCADA system, the following technical capabilities are required. IDEC Factory Solutions can provide all of them.

  • Extensive experience and knowledge in designing and building SCADA solutions
  • Ability to understand client needs and design optimal SCADA solutions based on those needs
  • Deep understanding of SCADA technology and ability to use it appropriately
  • Deep knowledge of how to effectively collect, analyze and process large amounts of real-time data
  • Ability to effectively integrate different systems and devices
  • Knowledge and technology to ensure the safety and security of systems
  • Project management skills and good communication skills with clients