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Electronic Batch Reporting

USE CASE BACKGROUND

Manufacturers in the life sciences sector understand the importance of accurate batch reporting.

The Food and Drug Administration (FDA) has strict requirements on what type of information must be recorded and accessible. FDA record keeping requirements under 21 CFR 211.188 include:

  • Accurate reproduction of production or control records.
  • Documentation of manufacturing steps for each batch, including production dates, identity of equipment/lines used, weights, identity of people supervising operational processes, labeling control records, yield statements, and measures of components used during the process.

Electronic batch reporting (EBR) streamlines the process for manufacturers, eliminating time-consuming manual data entry and validation, and the potential for human error.

Electronic Batch Reporting
Challenges

Challenges

Disparate equipment and systems. Manufacturers rely on a wide range of systems for data collection and process control, including PLCs, analytical instruments, SCADA systems, MES, historians, LIMS, and more. This presents a major hurdle for manufacturers trying to digitize their batch reporting process as these systems do not provide context for manufacturing data or easily integrate with enterprise IT systems. 

Logging relevant and required batch information. While required for regulatory reporting and process analysis, tracking batch data through production and packaging is challenging without a standardized model to collect and define the data. 

Approach

Approach

Native connections and modeling capabilities. Manufacturers who select and deploy HighByte Intelligence Hub at the Edge can securely connect disparate devices, files, databases, and systems via open standards and native connections. Powerful modeling tools enable them to create and govern standard data payloads. 

Real-time data assembly. HighByte Intelligence Hub allows users to assemble data in real time into EBR payloads prior to publishing to a unified namespace (UNS) or data lake in the Cloud. The Intelligence Hub is easily configured to publish data when batch events happen, like completion of a production step.

Benefits

Benefits

Information accessibility. The Intelligence Hub enables the collection and contextualization of data at much higher data resolutions from a much broader set of devices and systems than has previously been available. Regulatory and process optimization groups can quickly and easily access information to troubleshoot, optimize, and report on the production process.

Cost savings. The batch data model provides a complete view of the product environment. It can be used to catch quality issues early in batch processes, which can result in multimillion-dollar savings for batch manufacturers.

Reference Architecture

hb-electronicbatchreporting_orig

Customer Case Study

A contract development and manufacturing company (CDMO) wanted to track their drug product data and deliver comprehensive, real-time reporting to their supply chain as the product moved from bioreactor to delivery. They also wanted to reduce the amount of time required to identify the root cause of quality failures.
 
Creating a holistic batch report was extremely resource intensive because the data required was split between process equipment, historical databases, and lab quality instruments. These data sources had no association, were asynchronously generated, and had to be manually processed and analyzed. This process took several weeks to complete and resulted in entire batches being scrapped because quality mistakes were not caught soon enough.
 
This pharmaceutical CDMO deployed HighByte Intelligence Hub to automatically create a comprehensive batch report model to drive their reporting and speed root cause identification of quality failures. Using the Intelligence Hub, they were able to connect to disparate data sources, define data models that satisfied their business requirements, and publish the complete batch report for internal and external use. The batch data model merged disparate data sources into a simplified, complete view of the product environment. It was used to catch quality issues early in batch processes, resulting in multimillion-dollar savings.

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