IT retrofit

retrofit
Basics

What is the idea and advantage of an IT retrofit?

retrofit
Approach

What problems does an IT retrofit solve, and why is this path useful?

Equipment pharmaceutical industry

Which scenarios and advantages does the implementation have in the pharmaceutical industry?

Industry-
machinery

Which scenarios and advantages does the implementation of industrial machinery and equipment entail?

Stand-Alone Applications

In which single applications or devices can an IT retrofit be useful?

Econimics

Why is an IT retrofit much cheaper than a new machine, or a complete control upgrade?

retrofit Basics
  • Operators of (pharmaceutical) plants / machines are confronted with the problem that the PCs used in their systems / manufacturing machines get older, can not be (more) serviced on the software and hardware side, and thus a failure of the overall machine becomes more likely.

  • In case of such a failure, production can not continue.

  • In addition, there are extended, so far not coverable risks & problems in eg. Data backup & time synchronization.

  • In all cases considered, the machine works perfectly mechanically

retrofit Approach
  • The affected PCs are read out 1: 1 and the data, including the operating system, migrated to a state-of-the-art hardware

  • The new environment is placed in a current, up-to-date computer system using all previously accessed interfaces

  • The environment can be fully backed up, restored, and time synchronized independently of the operating system at any time. A replacement PC can be kept and replaced immediately to continue production

  • There is no interference with the implemented programming or control as well as the program environment

  • The PC system / system can continue to be used with appropriate risk analysis and partial requalification with greatly reduced default risk

Equipment pharmaceutical Industry

The retrofit of plants and machines of the pharmaceutical industry is more complicated than the other industrial sectors due to the necessary documentation and the GMP background. The following process is basically pursued:

The core of the procedure is two risk analyzes. First the feasibility in itself, then the effects and risks of the migration, on the basis of which the documents for IQ and OQ are created.

Tests for verification flow seamlessly into this.

If the requirements for components, hardware and GMP requirements are taken into account, a migration to a stable environment is possible.

 

Key Benefits:

 

  • Significant reduction in downtime

  • Reduction production risk

  • Hardware failure redundancy can be retrofitted

  • time synchronization

  • Backup implementable

  • No complete requalification necessary

  • Way cheaper than alternatives

 

Besides Advantages:

 

  • Processing speed +

  • Desaster Recovery

  • Possible integration into facility IT infrastructure

  • Maintenance / Support after migration

Industry machinery

As in the pharmaceutical industry, other industries also have specific capital goods that can not be easily exchanged and only at great financial expense.

If machines and equipment are working well mechanically, but control hardware in the form of PCs has become a critical component, then a retrofit can replace a costly new acquisition as a cheap alternative.

 

Again, the process begins with a feasibility study and analysis of the machine, whereupon the migration is planned and critical functions defined and later meticulously tested.

 

The advantages can be summarized as follows:

 

Key Benefits:

 

  • Significant reduction in downtim

  • Reduction production risk

  • Hardware failure redundancy can be retrofitted

  • time synchronization

  • Backup implementabl

  • Not cheaper than alternatives

 

Besides Advantages:

 

  • Processing speed +

  • Desaster Recovery

  • Possible integration into facility IT infrastructur

  • Care / Support after migration

Stand-Alone Applications / Systems

For the IT retrofit for individually operated systems, which are usually not complexly networked, several use cases are solvable.

As with the large systems, retrofit GmbH migrates the entire IT system environment to new hardware and components after Initialer analysis in order to keep older software running safely and to minimize hardware failure risks.

Due to the reduced complexity of such systems and applications, the implementation is usually easier and faster to handle, which is why these systems can be implemented unbureaucratic and above all cheaper.

This applies to machines / software / systems from all branches of industry, such as the steel paper, chemical industry, or in general all industrial processing applications.

The pharmaceutical industry, with its multitude of individual solutions for smaller appliances or measuring instruments, also counts here. A GMP documentation can not be omitted here, but the scope and thus effort is usually much lower.

Basically, the following operating systems can be covered:

For operating systems outside of a Microsoft environment, the case needs to be considered closely, and the challenges can be solved here as well.

Economics

Whether an IT retrofit should be performed depends not only on knock-out criteria, such as the obsolescence of devices or (spare) parts.

With many older machines, it makes sense to calculate how often and with what impact machines fail, over what time, and what the repair will cost in this case.

With many older machines, it makes sense to calculate how often and with what impact machines fail, over what time, and what the repair will cost in this case.

Against this background, it is relevant to be able to know or decide whether an IT retrofit is a valid economic option, whether "doing nothing" is an option, or evaluating a new investment in machinery and equipment in the context of a repair.

Against this background, it is relevant to be able to know or decide whether an IT retrofit is a valid economic option, whether "doing nothing" is an option, or evaluating a new investment in machinery and equipment in the context of a repair.

The template can be downloaded in the download area.

In the template, values ​​are predefined as an example, which describes a simpler layout of a completed project. The implementation of the IT retrofit has resulted in savings of around EUR 270.000, the costs of implementation have already been deducted. Depending on the produced goods and machine corner data, the savings can be higher

 
 
 
 
 
 
References

Feasibility study / IT retrofit / measuring system

retrofit GmbH, Raiffeisenstraße 2/2, D-71254 Ditzingen

Tel.: 0049 7156 71 10 770