All Posts By

e3imh

Risk Mitigation of Critical Data Loss

By | industry

Abstract

A commercial drug manufacturer in collaboration with E-Volve Systems implemented a critical monitoring system that required environmental data to be recorded in a 21 CFR Part 11 compliant manner.

With an intent to mitigate risk of data loss, the drug manufacturer chose Vaisala instrumentation to read and locally store environmental data. The Vaisala instrumentation chosen can store environmental data locally on the device and report environmental data to an OPC-compliant SCADA system.

The drug manufacturer had a need for a solution that moves data stored on the devices to the Rockwell Automation SCADA system in the event of data loss. E-Volve Systems provided a solution that detects data loss, recovers the lost data from the devices, and moves it to the SCADA system.

The solution included a Windows service that polls the SCADA for gaps in historian data. If a gap is found, the solution pulls data from the buffers and populates it into the SCADA system. This provides redundancy and verification that critical data resides in a single repository, ensuring data integrity. The customer relied solely on the existing SCADA and used the most robust instrumentation to protect against critical data loss.

Problem Statement

The end-user chose Vaisala instrumentation equipped with loggers that provide data buffering to protect against critical data loss. However, the buffering capability did not integrate “off the shelf” with the existing SCADA, Rockwell Automation FactoryTalk. The buffered data from the loggers did not automatically populate data to the historian after a SCADA outage.

Background

The architecture selection allowed the customer to deviate from the more typical control system implementation which would include PLCs and remote I/O nodes. The architecture consisted of 150+ Vaisala temperature and humidity sensors and data loggers mounted throughout the facility. The data loggers have a 10-year internal battery and a sample storage capacity that can store from days to years’ worth of data based on the number of connected sensors and the configurable sample interval. Each sensor was connected to a data logger which buffered data and transmitted real-time data to an OPC server. The OPC server was also the home of the custom solution described within.

Solution

The software solution developed was a Windows service designed to actively poll the historian to find gaps in critical data. This polling occurred on a configurable, timed interval. A gap in historical data could occur for a variety of reasons, including power loss, communication loss, or servers not running. Once a gap in data was identified, the service retrieved data from the instrument data loggers and populated the historian with missing data. If a critical data gap is detected and the solution is unable to retrieve data or unable to populate the data gap, a SCADA alarm is generated and relevant personnel are notified using WIN-911 notification software. The service is multithreaded, so it takes full advantage of the VMs available resources, reducing the time to recover from a critical data gap. This is especially useful when multiple critical data gaps have been created from different loggers, as data can be read from more than one logger simultaneously. The service is also able to fully recover from any system failure such as unexpected shutdown of the VM. The software solution decision tree that highlights the functionality is detailed below.

This service allowed the client to use their selected data loggers with their existing industry standard historian and SCADA system. It requires no action on the part of the client. The alternative that had been provided to client was a standalone system based around the data logger selection, which would have required separate specialized historian and reporting software to be purchased and maintained. This would mean separate reporting and trending tools for data for just one section of the plant. This would require additional training to use and considerable expansion of the virtual infrastructure. Additionally, a custom solution in the event of non-recoverable data setting off an HMI alarm would have been required.

Conclusion

The solution has been validated, is now running, and has successfully inserted otherwise lost critical data. Currently, power/communication could be lost for 3 months and the provided solution would insert critical data for all 150+ sensors upon communication restoration. This solution has allowed the end-user to implement a critical monitoring system that consists of instrumentation that connects directly to the existing SCADA system. This eliminated the need for multiple sources of critical data, as well as a programmable logic controller with remote input/output nodes spread across the facility.

Request Service Online

By | industry

We’re taking our service one step further. 

E-Volve Systems is rolling out an online Support Platform to better serve the service needs of our customers. We understand that your time is valuable, especially when an issue arises. We want to make that experience as painless as possible.  

 E-Volve Systems’ Support Platform is designed to simplify your support needs by providing you with: 

  • An easy-to-use, efficient online and mobile-responsive portal that accepts service requests 24/7 
  • Intuitive work order creation that walks you step-by-step to provide job information 
  • Automated job status updates to always keep you up-to-date 
  • Online bill-pay options  

You can find this portal at: https://support.e-volvesystems.com  


E-Volve Systems continues to be dedicated to making your industrial process run reliably and efficiently.  

Thank you for your time and please reach out to us if you have any inquiries! 

 info@e-volvesystems.com

877.302.1788 

Cincinnati Teamwork

By | industry

Our Cincinnati office had a great time “escaping” from the Oval Office today at Houdini’s Escape Room. We escaped with time to spare thanks to collaboration and teamwork!

Event Presentation

By | industry

E-Volve Systems’ President, Kevin Stout was recently invited to present at an event sponsored by ARMI/BioFab, IEEE, and Rockwell Automation entitled Automation and Data Management for the Manufacture of Tissue Engineering & Regenerative Medicine (TERM) Products. Kevin spoke to a large group of TERM experts about the benefits of automation and the proper process of planning automation implementation. The field of tissue engineering and regenerative medicine holds enormous potential to restore and improve damaged tissues, cartilage and even whole organs. The FDA has recently announced policy framework to facilitate and expedite the availability of therapies to patients with serious, or potentially life-threatening conditions. As this field continues to evolve, work is underway to make large-scale manufacturing of engineered tissues a reality. Our cutting-edge solutions support scalability and standardization of this process. We are excited to be part of an industry that will have such a positive impact on so many, and we look forward to adding value however we can in the advancement of this field.

E-Volve Systems at TERM Workshop

By | industry

E-Volve Systems’ President, Kevin Stout was recently invited to present at an event sponsored by ARMI/BioFab, IEEE, and Rockwell Automation entitled Automation and Data Management for the Manufacture of Tissue Engineering & Regenerative Medicine (TERM) Products. Kevin spoke to a large group of TERM experts about the benefits of automation and the proper process of planning automation implementation.

TERM (Tissue Engineering & Regenerative Medicine)

The field of tissue engineering and regenerative medicine holds enormous potential to restore and improve damaged tissues, cartilage and even whole organs. The FDA has recently announced policy framework to facilitate and expedite the availability of therapies to patients with serious, or potentially life-threatening conditions.

As this field continues to evolve, work is underway to make large-scale manufacturing of engineered tissues a reality. Our cutting-edge solutions support scalability and standardization of this process.

We are excited to be part of an industry that will have such a positive impact on so many, and we look forward to adding value however we can in the advancement of this field.

To learn more about ARMI (Advanced Regenerative Manufacturing Institute) visit their website at https://www.armiusa.org/

Biotech Week Boston 2018

By | industry

E-Volve Systems is proud to announce that our own, Vivek Puthezath, was chosen as a keynote speaker for Biotech Week Boston 2018.  Mr. Puthezath was a guest for Cell & Gene Therapy Bioprocessing & Commercialization unit where he spoke about Automation in Large-Scale Engineered Tissue Manufacturing. Mr. Puthezath highlighted the benefits of using S-88 Batch techniques in large scale tissue manufacturing and how these techniques can allow tissue engineering to be scalable and reproducible. He also touched on how you can apply modular control strategy across multiple bioreactors, resulting in consistent data across all unit operations. For more information or if you have any questions, please feel free to reach out to us at info@e-volvesystems.com

E-Volve Systems makes Inc. 5000 for third year in a row!

By | industry

Inc. Magazine Unveils Its 37th Annual List of America’s Fastest-Growing Private Companies

For the 3rd Time, E-Volve Systems, L.L.C. Appears on the Inc. 5000, Ranking No. 1687 With Three-Year Revenue Growth of 273 Percent

NEW YORK, August 15, 2018 – Inc. magazine today revealed that E-Volve Systems, L.L.C. is No. 1687 on its 37th annual Inc. 5000, the most prestigious ranking of the nation’s fastest-growing private companies. The list represents a unique look at the most successful companies within the American economy’s most dynamic segment—its independent small businesses. Microsoft, Dell, Domino’s Pizza, Pandora, Timberland, LinkedIn, Yelp, Zillow, and many other well-known names gained their first national exposure as honorees on the Inc. 5000.

“E-Volve Systems is very excited to be included on the Inc. 5000 list for the third time in a row!  We would like to thank Inc.com for facilitating the Inc. 5000 list and we would like to congratulate all companies that have been named.

I would to credit our clients and most notably, a very talented and dedicated engineering and management team for our growth in recent years.  I founded E-Volve Systems 8 years ago to improve the methods in which Industrial Automation helps manufacturers achieve efficiency, productivity and quality.  Without the hard work and dedication of both our team and our clients, our accomplishments would not be possible today.

Thanks again to Inc. and we hope to see you next year!

Kevin Stout

President and Founder

E-Volve Systems”

Not only have the companies on the 2018 Inc. 5000 been very competitive within their markets, but the list as a whole shows staggering growth compared with prior lists. The 2018 Inc. 5000 achieved an astounding three-year average growth of 538.2 percent, and a median rate of 171.8 percent. The Inc. 5000’s aggregate revenue was $206.1 billion in 2017, accounting for 664,095 jobs over the past three years.

Complete results of the Inc. 5000, including company profiles and an interactive database that can be sorted by industry, region, and other criteria, can be found at www.inc.com/inc5000.

New Signage

By | industry

We’re pretty excited to see that our signage has been mounted at the new Merrimack, NH office. If you’re in the northeast and you haven’t visited our new office, you should contact us and check it out!