Digital Solutions
At KeyPlants Automation, we offer cutting-edge digital solutions that enhance efficiency, reliability, and compliance across regulated industries. Our expertise spans data integration, advanced process modeling, and digital twin technology, ensuring seamless digitalization of production environments.
MES
Digital Twin & Process Simulation
A Manufacturing Execution System (MES) is essential for digitalizing production, improving efficiency, and ensuring compliance in regulated industries. At KeyPlants Automation, we help clients transition from manual workflows to fully digital, integrated manufacturing processes.
Compliance & Data Integrity:
Eliminate paper-based processes with electronic batch records (eBR) and electronic work instructions (EWI) for accurate and traceable documentation.
Operational Efficiency:
Automate production scheduling, resource management, and real-time monitoring, improving OEE, reducing downtime, and increasing throughput.
Quality & Process Control:
Minimize human errors, standardize workflows, and enforce correct material and equipment usage.
System Integration:
Seamlessly connect MES with ERP, LIMS, QMS, and automation systems (DCS, PLC/SCADA) for optimized data flow and batch execution.
We leverage digital twin technology to accelerate automation system development, enabling parallel design, validation, and testing activities. By simulating process behavior in a virtual environment, we can refine control strategies, troubleshoot issues, and optimize system performance before deployment—reducing commissioning risks and ensuring a seamless transition to full-scale production.
Predictive Analytics:
Identify and mitigate potential issues before they impact production, using advanced process modeling tools.
Virtual Commissioning:
Reduce risks and costs by simulating automation systems before physical implementation.
Continuous Optimization:
Improve efficiency and performance by leveraging real-time insights from digital models.
Operator Training:
Accelerate production start-up with immersive, hands-on training in a risk-free virtual environment.
A Manufacturing Execution System (MES) is essential for digitalizing production, improving efficiency, and ensuring compliance in regulated industries. At KeyPlants Automation, we help clients transition from manual workflows to fully digital, integrated manufacturing processes.
Compliance & Data Integrity:
Eliminate paper-based processes with electronic batch records (eBR) and electronic work instructions (EWI) for accurate and traceable documentation.
Operational Efficiency:
Automate production scheduling, resource management, and real-time monitoring, improving OEE, reducing downtime, and increasing throughput.
Quality & Process Control:
Minimize human errors, standardize workflows, and enforce correct material and equipment usage.
System Integration:
Seamlessly connect MES with ERP, LIMS, QMS, and automation systems (DCS, PLC/SCADA) for optimized data flow and batch execution.
We leverage digital twin technology to accelerate automation system development, enabling parallel design, validation, and testing activities. By simulating process behavior in a virtual environment, we can refine control strategies, troubleshoot issues, and optimize system performance before deployment—reducing commissioning risks and ensuring a seamless transition to full-scale production.
Predictive Analytics:
Identify and mitigate potential issues before they impact production, using advanced process modeling tools.
Virtual Commissioning:
Reduce risks and costs by simulating automation systems before physical implementation.
Continuous Optimization:
Improve efficiency and performance by leveraging real-time insights from digital models.
Operator Training:
Accelerate production start-up with immersive, hands-on training in a risk-free virtual environment.
FAQ
FAQ
How does MES reduce compliance risks in pharmaceutical manufacturing?
MES implementations enforce compliance by:
- Automating ALCOA+ data capture for full audit trails
- Embedding GMP workflows that prevent procedural deviations
- Integrating with QMS for automatic CAPA initiation on exceptions.
What’s the business case for digital twin technology?
Digital twins justify their cost by compressing project timelines and accelerating production readiness:
- Cut commissioning activities by 40% through virtual FAT/SAT
- Reduce development rework by stress-testing control logic upfront
- Start operator training months earlier with risk-free simulations
Most clients achieve full ROI within 12 months from avoided downtime and faster qualification alone.
How is legacy equipment integrated with modern MES platforms?
Legacy integration requires a layered approach combining protocol conversion, data normalization, and phased deployment. Industrial IoT gateways enable connectivity for non-networked devices, while middleware solutions handle data transformation and routing using standard industrial communication protocols. The implementation maintains production continuity through parallel operation during cutover, with rigorous data validation ensuring ALCOA+ compliance throughout migration.
Successful integration preserves existing equipment functionality while enabling full MES capabilities including electronic batch records, equipment tracking, and automated reporting - all without disrupting validated production systems.
Siemens gProms & SIMIT Implementation
KeyPlants Automation is currently developing an advanced digital twin for pharmaceutical spray drying using Siemens gProms and SIMIT. We've successfully simulated core process dynamics, achieving 95% model accuracy during initial validation. The project now focuses on expanding the virtual environment to cover full batch cycles and cleaning processes.
This scalable solution already demonstrates how digital twins can reduce commissioning risks—with early results showing 30% faster control logic testing. Our modular approach allows gradual expansion from single-unit simulation to full production line integration, while maintaining compliance with COMOS PAA standards for parallel development.
MES: The Digital Backbone of Modern Pharma
Modern Manufacturing Execution Systems (MES) transform regulated production by replacing error-prone paper records with electronic batch records (eBRs) that enforce compliance automatically. At KeyPlants, we implement MES solutions that deliver:
- Real-time release testing through integrated PAT data
- Automated deviation handling with built-in CAPA workflows
- End-to-end traceability from raw materials to finished goods
And the result? Facilities achieve 30% faster batch release cycles while reducing compliance risks by up to 55% compared to manual systems.
Digital Solutions That Transform Manufacturing
Digital Solutions That Transform Manufacturing
We design, implement, and optimize digital systems for pharmaceutical and industrial manufacturers who need to:
- Replace paper workflows with automated, error-proof execution
- Unlock process insights through integrated data analytics
- Future-proof operations with modular, scalable architectures
Our methodology combines proven digital frameworks with cutting-edge technologies—from MES and digital twins to IIoT and predictive analytics—delivering systems that meet today’s compliance demands while adapting to tomorrow’s innovations.
Let’s digitize your competitive edge.
