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Case Studies

Custom Automation Solutions designed, installed, and maintained by iCore.

iCore Automation has also developed a couple custom solutions (products) that met the needs of their clients.

View full list of Project Experience 

Cerial Box

Pharmaceutical Client – Durham, NC​

The cerial box was developed as a cost savings and to reduce the downtime of the process. Using this Cerial Box, iCore Automation was able to trouble-shoot the Watson-Marlow Pumps in real-time and in a Grade A environment.  This reduced the downtime and also the need to send out pumps that didn’t need repairing.

Badger

Pharmaceutical Client – Hospira, KS

The Badger system was developed to address a warning letter from the FDA. iCore Automation designed and implemented this system which automated the Visual Inspection for Pfizer’s Visual Inspection Stations. Operators used to manually log their visual inspection times, which left room for several errors. iCore Automation was able to automate the system to use the employee security badges and allow for electronic data collection of the run time and visual inspection time which aligned with their SOPs. Presently Pfizer has requested some additional features that we are implementing in 2018.

Visual Inspection Tracking System

Pharmaceutical Client – Hospira, KS

THE VITS system was scoped to update the Badger system to meet new regulatory commitments. The system software was re-designed to include more hardware and software components to allow additional tracking of product defects by inspector. The data is collected, stored, reported and evaluated for defect tracking purposes. The system was installed and qualified late 2017 to allow the customer to meet regulatory commitments and establish a base for the future of their defect tracking program.

Project Experience

iCore Automation, takes pride in offering not only industry leading automation but also turn-key solutions for their clients. iCore Automation works with their clients to fully understand the issues surrounding their obstacles in order to provide the most economical and reliable solution. Below are some of the projects that iCore Automation resources have been a part of.

Manufacturing Facility, Longmont, CO

1997 - 2001

  • Assisted with Start-up 
and ICOs and ACOs.
  • Provided design and controls for the Roller Bottle Fill & Withdrawal (RBM)
  • Re-designed Incremental Encoder for bottle tracking
  • Provided PLC and SCADA support for Cell Culture area and Chromatography Skids
  • Provided automation assistance to several groups within the engineering department
SCADA/ControlNet Upgrades, Boulder & Longmont, CO

2002-2003

  • Responsible for management, cost control and scheduling of all personnel 

  • Develop Build procedure for SCADAs and revise R/Ds and SOPs 

  • Assist with the development of the IQ/OQs 

  • Tested new SCADA/Clients on test network prior to field start-up 

  • Firmware upgrades for all PLCs and Remote I/O modules 

Manufacturing Expansion Project, Boulder, CO

2001

  • Assisted with Start-up 

  • Provided automation assistance with the Utility systems; WFI, CSG and Chillers 

  • Performed Ethernet side card firmware upgrades 

  • Assisted with Validation of several systems within the manufacturing facility 

Cell Culture Expansion Project, Boulder, CO

2004-2005

  • Provided technical support of all Process Automation (Controllogix, PLC5 & SLCs / iFIX SCADA) for Bioreactors, Media Prep and Media Hold, CIP System, Utility System and Electrical Systems. 

  • Acting Liaison between Amgen and System Integrators 

  • Assisted Validation with technical issues concerning the IQ/OQs 

  • Performed SDT and provided design support 

  • Managed and assisted Vendor personnel with several SKID installations and start-up
SCADA Upgrade Project, Longmont, CO

2007

  • Development of IOQs 

  • Development of Function Tests 

  • Provide technical support resolution of Network communication issue 

Control System Upgrade, Hayward, CA

2007-2008

  • Scope of work included management, scheduling, document generation, system design and system start-up for the Process Utility Controls System (PUCS) 

  • Automation support of Controllogix PLC, SLC 500, Siemens S7, PanelView, iFIX SCADA, Development of SOPs and SDD 

  • Design and Implement SCADA/CLIENT Network Architecture on MS 2003 Server 

  • Provide technical support of the following: 
WFI System
, Pure Steam Generator System, CIP System, RODI System
, CDA System
, and Waste Neutralization (Siemens) 

  • Implement HAMO (Steris) Parts Washer via OPC Server/Client communication 

Wastewater Project, Boulder, CO

2008-2009

  • Scope of work included management, scheduling, Project Status Reporting

  • Supervision of Engineers to meet deliverables 

  • Technical Lead on all SCADA, PLC and Historian design and implementation 

  • Attend weekly project meetings to discuss schedule and project road blocks 

  • Scope of work included the integration of the following systems: Waste Neutralization System, Acid Day Tank
, Caustic Day Tank, Lift Stations
, Sump Pumps
, Surge Tank
 and Frac Tank
OSI Pi and RtReports Support, Thousand Oaks, CA

2009

  • Develop RtReports for TOFX Project 

  • Support Control Systems (DCS, PLC, HMI, HIST) 

  • Install Pi Tag Additions for TOFX Project 

  • Support BAS Inter-processor Communication 

  • Provide Support for OSI Pi and DeltaV Communication 
with DeviceNet
Robot and PLC/DCS support, Durham, NC

2009

  • Support Staubli Robots 

  • Develop AOQs for Robot Automation Qualifications 

  • CRF/ACC generation/implementation for Robot System changes 

  • RS and DDS review 

  • SLC500 and PanelView 1000 trouble-shooting 

  • DeltaV/Batch Operation and trouble-shooting 

  • Assist in the commissioning and qualification of the 12 robot systems 

  • Assist in execution of Incubator OQ testing
Tech Transfer Project - Robot and Process Automation support, CA

2009

  • Support ABB Robotic Storage and Handling System (ABB & RS5000)
  • Support Production runs
  • Work Order Implementation using Maximo 

  • Change control for Automation Systems
  • Develop PI Notification Strategy for B7 

  • Lead PI Tag configuration and implementation
  • Support Bioreactors (PLC5), UFDF (SLC5/04), and RBM (Mitsubishi PLC & HMI) 

Manufacturing Facility – DeltaV, Robot and Process Automation support, CA

2009

  • Support Upgrade for Emerson DeltaV DCS for Bioreactors and UFDF
  • Support Production runs and ONCALL support
  • Work Order creation and implementation
  • Data Integrity Solutions and Consulting
  • Create Templates for PI Notifications
  • Create Validation Process for PI tag qualification
  • Create PI tag Standards for Building 7