Successful process analyzer implementation

The first part of this chapter (Section 15.2) discusses the value of and challenges involved in implementing NIR technology in the chemical industry. It also describes a process for successful process analyzer implementation. Similar issues as they relate to the pharmaceutical industry are covered in Chapter 2. The second part of this chapter (Section 15.3) gives a number of examples of actual NIR applications in the chemical industry, which serve both to illustrate the points from the first part and to demonstrate the range of applications for NIR technology. 

The following factors increase the likelihood of success for an NIR process analyzer implementation. 

Successful and effective implementation of a process safety metrics system is done by first defining the structure for the system. The structure or framework includes how data is collected, analyzed, and shared with the organization. The framework defined in this section will add more detail to the overall objectives and goals earlier in the chapter and will provide a foundation for the analysis conducted in the next section of this chapter. 

Specialists should be relied on for development of NIR process analysis applications. Routine analyzer and NIR method maintenance are also critical components in the success of the implementation of process NIR methods. Either the instrument can drift or the samples can vary. It is preferable to perform analyzer and method maintenance procedures automatically, for example, through control charting, rather than requiring a specialist (1). 

This book is presented from the viewpoint of a spectroscopist, and as such focuses on spectroscopic tools, while also providing some guidance on important considerations for the successful implementation of an analyzer to moifitor and control a process. Regardless of the industry in which PAT is used, there is a need to focus on the science and use these tools in the scientific understanding of processes and in the manufacture of quahty product, consistently. 

Defining a Problem Statement The first step in successfully implementing an automation project is to clearly define the problem that needs to be solved. Automation can solve a number of different problems. Each laboratory must ask itself which specific problems it wants to solve. The best place to start is in thinking about the needs of the laboratory. Is there a need to analyze more samples with fewer people or to shorten sample turnaround time Is there a need to increase the consistency of an assay or process Is there a need to reduce exposure to hazardous materials or to minimize operator fatigue or repetitive motion injuries Is there a need to reduce the cost per sample Is there a need for a process to run overnight or over the weekend ... 

---