Failure analysis – Bosch offers data mining as new pharma service

Bosch Packaging at Achema – Frankfurt – 11 to 15 June 2108

Examine large amounts of data for the smallest effects. Photo: Bosch

At Achema, Bosch Packaging Technology will present its new data mining service, which has recently been added to the range of pharma services for solid dosage forms. The service is offered by the Bosch subsidiary Hüttlin. The aim is to evaluate existing machine data more effectively to identify and eliminate root causes. “So far, about 50% of deviations have been classified as ‘human error,’” says Dr Marc Michaelis, expert for continuous production and process verification at Hüttlin. “Yet we assume that this is true for no more than 10%. The rest is often misinterpreted due to missing information. As a matter of fact, there is already enough data available to get to the bottom of the causes. However, there is a lack of knowledge and time to read this data correctly.” First projects have shown that new patterns and failure causes can be defined and remedied in the production process thanks to data mining, and can help to achieve a more stable product quality in the long run.

Correct interpretation of machine data

ID 1356380 Bosch Data Mining Visualisierung
Using the data mining took
developed by Bosch, feature
extractions of machine data can be
visualized. Photo: Bosch

Thanks to Bosch’s data mining tool, it is now possible to examine large amounts of data for the smallest effects using statistical methods. In general, the data from two production batches is already sufficient to draw first conclusions. The more data is available for evaluation over a longer period, the more details can be identified. All it takes is machine sensors, which already collect data on almost all historical machines, as well as the right tool to disclose the data. “Large investments are not required to use the existing data more effectively. The key to success lies in merging knowledge from different disciplines,” says Michaelis. “Bosch not only has the necessary technical expertise, but also extensive
process knowledge in customers’ product manufacturing. To identify reasons for process deviations, which are not obvious at first sight, we teamed up with the statistics experts from our Bosch Center for Artificial Intelligence in Germany and the US. Together we will raise the data treasure.” The potential of this approach has already been demonstrated successfully in different customer projects. For instance, when a customer suddenly produced a ‘out of specification’ (OOS) batch, the Bosch experts systematically got to the
bottom of things. The recorded data showed that a particular valve was responsible for the deviation. However, the valve had been excluded beforehand since it was considered uncritical in terms of product quality. Thanks to the data analysis, deeper correlations and an undetected cascade of connections could be identified. “Eventually, we found out that the valve provided an indirect indication of a false gas flow in the system, which was not visible at first sight. The problem could then be easily solved by recalibrating the system,” Michaelis explains.

Maintaining consistently high quality

Consistently high product quality is a critical factor in the pharmaceutical industry, since authorities such as the FDA and EMA have strict guidelines for process understanding, monitoring and validation. “To make successful root cause analyses and process improvements, or to develop a control strategy as part of continuous process verification, we offer customers our new data mining service,” Michaelis says. “We are looking forward to further projects to pursue the path of industry 4.0 together with our customers.” Bosch Packaging Technology will be present at Achema in Hall 3.1, Stand C71.

The impact, resilience, and growth of responsible packaging in a wide region are daily chronicled by Packaging South Asia.

A multi-channel B2B publication and digital platform such as Packaging South Asia is always aware of the prospect of new beginnings and renewal. Its 16-year-old print monthly, based in New Delhi, India has demonstrated its commitment to progress and growth. The Indian and Asian packaging industries have shown resilience in the face of ongoing challenges over the past three years.

As we present our publishing plan for 2023, India’s real GDP growth for the financial year ending 31 March 2023 will reach 6.3%. Packaging industry growth has exceeded GDP growth even when allowing for inflation in the past three years.

The capacity for flexible film manufacturing in India increased by 33% over the past three years. With orders in place, we expect another 33% capacity addition from 2023 to 2025. Capacities in monocartons, corrugation, aseptic liquid packaging, and labels have grown similarly. The numbers are positive for most of the economies in the region – our platform increasingly reaches and influences these.

Even given the disruptions of supply chains, raw material prices, and the challenge of responsible and sustainable packaging, packaging in all its creative forms and purposes has significant headroom to grow in India and Asia. Our context and coverage engulf the entire packaging supply chain – from concept to shelf and further – to waste collection and recycling. We target brand owners, product managers, raw material suppliers, packaging designers and converters, and recyclers.

In an admittedly fragmented and textured terrain, this is the right time to plan your participation and marketing support communication – in our impactful and highly targeted business platform. Tell us what you need. Speak and write to our editorial and advertising teams! For advertisement , for editorial and for subscriptions

– Naresh Khanna

Subscribe Now


Please enter your comment!
Please enter your name here