© process analysis & automation 2005 short course “i want to automate that process” malcolm...
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© Process Analysis & Automation 2005
Short CourseShort Course
“I want to Automate that Process”
Malcolm Crook
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© Process Analysis & Automation 2005
Key questionsKey questions
• Where do you want to automate ?• Why do you want to automate ?• What do you want to automate ?• How do you want to automate ?• When do you want to automate ?
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Course contentsCourse contents
• Choice of method
• Choice of equipment
• Choice of robot or stacker
• Choice of scheduler (pre-emptive/real-time)
• Automated method design
• Documentation of projects
– URS FDS FATs SATs
• Data handling
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WhereWhere do you want to automate ? do you want to automate ?
• Location• Access• Floor• Facilities
– Compressed air– Vacuum– Power– IT Network access
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WhyWhy do you want to automate ? do you want to automate ?
• Increased throughput• Improved data quality• Plate tracking• Sample identification• Reduced analysis cost• Safety
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HowHow do you want to automate ? do you want to automate ?
• partial automation• complete automation• definition of success• data handling• integrator
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Golden Rules of AutomationGolden Rules of Automation
If it doesn’t work manually …
… it won’t work more efficiently, if you automate it!
Just because it works manually …
… doesn't mean it will work, if you automate it!
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IntegrationIntegration
Automated systems have to be build and integrated • DIY• Single provider• Independent integrator
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WhenWhen do you want to automate ? do you want to automate ?
• All at once• Step by step
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WhatWhat do you want to automate ? do you want to automate ?
• Small– instrument only connections– no robots– Stacker versus laboratory robot
• Medium– workcells– small static robots
• Large– systems, distributed processing– tracked robots
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Choice of equipmentChoice of equipment
Usually• decided by the science• methods have been decided• equipment has been decided• automating a manual method
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Choice of automationChoice of automation
• Budget• No of pieces of equipment• Reliability• Safety• Laboratory space
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Choice of robot or stackerChoice of robot or stacker
• Types– Stackers– Laboratory robot– Factory robot
• Every integrator has a favourite• Most customers have favourites
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StackersStackers
Positives• Commercially available• 1-2 instrument access
Negatives• Poor data handling• 1-2 instrument access
Best system• OVERLORD • Stacker• instrument
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Stacker exampleStacker example
• OVERLORD™• RapidPlate• GE LEADseeker• Barcode reader• Data handling• Plate tracking
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Laboratory robotsLaboratory robots
Positives• Small• Versatile• Safe
Negatives• reliability
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Laboratory robotsLaboratory robots
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Factory robotsFactory robots
Positives• Accurate• Reliable
Negatives• Needs screening
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Factory robotsFactory robots
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Small automated systemsSmall automated systems
• Small– instrument only connections– no robots
• Analysis or sample preparation method• Devices to undertake method• System consists of
PCsoftware to control the system
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Medium automated systemsMedium automated systems
• Medium– workcells– small static robots– <= 5 instruments
• load and unload operations• plate reader• plate washer• diluter• System consists of
PCsoftware to control the systemrobot stack & instrument
instrumentrobot
stacks
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Low volume dispenserLow volume dispenser
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High resolution plate readerHigh resolution plate reader
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Microscopy systemMicroscopy system
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Pipetting stationPipetting station
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High Volume DispenserHigh Volume Dispenser
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Large automated systemsLarge automated systems
• Large– distributed processing– unipoint robot– tracked robots– multiple workcell tracked system
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Multiple work cell tracked systemMultiple work cell tracked system
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EnclosuresEnclosures
Why do you need ?• Safety• Protect experiment• Key access
Options• Extraction system
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Choice of schedulerChoice of scheduler
• pre-emptive• real-time
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Scheduling - Pre-emptiveScheduling - Pre-emptive
• Pre-emptive– static– run optimised before equipment moves– simple to set up– not good on error recovery or flexibility
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Scheduling - real timeScheduling - real time
• Real-time– flexible– good at error recovery– poor on MULTIPLE key timings
e.g Incubations, Shaking
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Automated method designAutomated method design
• Sub divide process into logical steps• Have one global routine• Teach all the robot moves as
– “get …” and “put …”• Combine routines to make sub units
– “load plate reader and run method”
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Interfacing to LIMS & data sourcesInterfacing to LIMS & data sources
• LIMS is a mature market• the main problem is data acquisition• most LIMS offer data collection from single instruments• most data sources
– high data throughput– complex robotic systems
• need to offer more comprehensive interface to LIMS
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Current IntegrationCurrent Integration
Laboratory Information Management System
Instruments
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Automated workcellsInstrumentsInstruments
Target TopographyTarget Topography
Laboratory Information Management System
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What is the Integration LayerWhat is the Integration Layer
Automated workcellsInstruments
Integration layer
Laboratory Information Management System
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What is the Integration LayerWhat is the Integration Layer
Automated workcellsInstruments
OVERLORD™
Laboratory Information Management System
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How OVERLORD can be used in the How OVERLORD can be used in the Integration LayerIntegration Layer
OVERLORD has• choice of external calling protocols• full file reading ability
– text file/csv– Microsoft Access– SQL
• ability to control most instruments• ability to control most automated workcells
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CommunicationCommunication
• Indirect – A CSV file is used to exchange data • Direct – OVERLORD interfaces directly to LIMS
– e.g Use ODBC
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Indirect CommunicationIndirect Communication
ADVANTAGES
• All LIMS can communicate using CSV Files
• Easy to integrate
DISADVANTAGES
• Error handling is poor in an Automated System
• Limited Data Exchange
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Direct CommunicationDirect Communication
ADVANTAGES
• Integration is more efficient• Access more data• Error Recovery
DISADVANTAGES
• More time needed to set up the integration
• Greater understanding of the LIMS required
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Which integration method is best?Which integration method is best?
• Depends on volume of data and type of data
• Use Indirect if….– low data exchange– data is only being ‘pushed’
• Use Direct if….– great level of data exchanged– Automated system runs off the data from LIMS
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Documentation of projectsDocumentation of projects
• Why document ?• User Requirement Specification (URS)• Functional Design Specification (FDS)• Factory Acceptance Tests (FATs)• Site Acceptance Tests (SATs)
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User Requirement Specification (URS)User Requirement Specification (URS)
• Tell a supplier what you want
• Instrument choices• Full methods• Throughput• Data handling• Aspirations
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Functional Design Specification (FDS)Functional Design Specification (FDS)
• Get what you want
• Full details of how URS will be achieved
• Signed agreement point
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Factory Acceptance Tests (FATs)Factory Acceptance Tests (FATs)
• See what you want exists
• Demonstration of an agreed set up of tests• Usually down with water
– Sign each test as completed
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Site Acceptance Tests (SATs)Site Acceptance Tests (SATs)
• Receive what you want
• Retest some or all of the FDS test• Run with real materials• Sign each test as completed
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In summary ...In summary ...
The key points are:• Decide what you want to do very carefully• Plan plan and plan again• Write a detailed URS• Engage a suitable integrator• Follow the project• Stay involved• Be prepared to learn