© Process Analysis & Automation 2005 Short Course “I want to Automate that Process” Malcolm Crook

© Process Analysis & Automation 2005 Key questions Where do you want to automate ? Why do you want to automate ? What do you want to automate ? How do you want to automate ? When do you want to automate ?

© Process Analysis & Automation 2005 Course contents Choice of method Choice of equipment Choice of robot or stacker Choice of scheduler (pre-emptive/real-time) Automated method design Documentation of projects –URS FDS FATs SATs Data handling

© Process Analysis & Automation 2005 Where do you want to automate ? Location Access Floor Facilities –Compressed air –Vacuum –Power –IT Network access

© Process Analysis & Automation 2005 Why do you want to automate ? Increased throughput Improved data quality Plate tracking Sample identification Reduced analysis cost Safety

© Process Analysis & Automation 2005 How do you want to automate ? partial automation complete automation definition of success data handling integrator

© Process Analysis & Automation 2005 Golden Rules of Automation If it doesn’t work manually … … it won’t work more efficiently, if you automate it! Just because it works manually … … doesn't mean it will work, if you automate it!

© Process Analysis & Automation 2005 Integration Automated systems have to be build and integrated DIY Single provider Independent integrator

© Process Analysis & Automation 2005 When do you want to automate ? All at once Step by step

© Process Analysis & Automation 2005 What do you want to automate ? Small –instrument only connections –no robots –Stacker versus laboratory robot Medium –workcells –small static robots Large –systems, distributed processing –tracked robots

© Process Analysis & Automation 2005 Choice of equipment Usually decided by the science methods have been decided equipment has been decided automating a manual method

© Process Analysis & Automation 2005 Choice of automation Budget No of pieces of equipment Reliability Safety Laboratory space

© Process Analysis & Automation 2005 Choice of robot or stacker Types –Stackers –Laboratory robot –Factory robot Every integrator has a favourite Most customers have favourites

© Process Analysis & Automation 2005 Stackers Positives Commercially available 1-2 instrument access Negatives Poor data handling 1-2 instrument access Best system OVERLORD Stacker instrument

© Process Analysis & Automation 2005 Stacker example OVERLORD™ RapidPlate GE LEADseeker Barcode reader Data handling Plate tracking

© Process Analysis & Automation 2005 Laboratory robots Positives Small Versatile Safe Negatives reliability

© Process Analysis & Automation 2005 Laboratory robots

© Process Analysis & Automation 2005 Factory robots Positives Accurate Reliable Negatives Needs screening

© Process Analysis & Automation 2005 Factory robots

© Process Analysis & Automation 2005 Small automated systems Small –instrument only connections –no robots Analysis or sample preparation method Devices to undertake method System consists of PC software to control the system

© Process Analysis & Automation 2005 Medium automated systems Medium –workcells –small static robots –<= 5 instruments load and unload operations plate reader plate washer diluter System consists of PC software to control the system robot stack & instrument instrument robot stacks

© Process Analysis & Automation 2005 Low volume dispenser

© Process Analysis & Automation 2005 High resolution plate reader

© Process Analysis & Automation 2005 Microscopy system

© Process Analysis & Automation 2005 Pipetting station

© Process Analysis & Automation 2005 High Volume Dispenser

© Process Analysis & Automation 2005 Large automated systems Large –distributed processing –unipoint robot –tracked robots –multiple workcell tracked system

© Process Analysis & Automation 2005 Multiple work cell tracked system

© Process Analysis & Automation 2005 Enclosures Why do you need ? Safety Protect experiment Key access Options Extraction system

© Process Analysis & Automation 2005 Choice of scheduler pre-emptive real-time

© Process Analysis & Automation 2005 Scheduling - Pre-emptive Pre-emptive –static –run optimised before equipment moves –simple to set up –not good on error recovery or flexibility

© Process Analysis & Automation 2005

Scheduling - real time Real-time –flexible –good at error recovery –poor on MULTIPLE key timings e.g Incubations, Shaking

© Process Analysis & Automation 2005

Automated method design Sub divide process into logical steps Have one global routine Teach all the robot moves as –“get …” and “put …” Combine routines to make sub units –“load plate reader and run method”

© Process Analysis & Automation 2005 Interfacing to LIMS & data sources LIMS is a mature market the main problem is data acquisition most LIMS offer data collection from single instruments most data sources –high data throughput –complex robotic systems need to offer more comprehensive interface to LIMS

© Process Analysis & Automation 2005 Current Integration Laboratory Information Management System Instruments

© Process Analysis & Automation 2005 Automated workcellsInstruments Target Topography Laboratory Information Management System

© Process Analysis & Automation 2005 What is the Integration Layer Automated workcellsInstruments Integration layer Laboratory Information Management System

© Process Analysis & Automation 2005 What is the Integration Layer Automated workcellsInstruments OVERLORD™ Laboratory Information Management System

© Process Analysis & Automation 2005 How OVERLORD can be used in the Integration Layer OVERLORD has choice of external calling protocols full file reading ability –text file/csv –Microsoft Access –SQL ability to control most instruments ability to control most automated workcells

© Process Analysis & Automation 2005 Communication Indirect – A CSV file is used to exchange data Direct – OVERLORD interfaces directly to LIMS –e.g Use ODBC

© Process Analysis & Automation 2005 Indirect Communication ADVANTAGES All LIMS can communicate using CSV Files Easy to integrate DISADVANTAGES Error handling is poor in an Automated System Limited Data Exchange

© Process Analysis & Automation 2005 Direct Communication ADVANTAGES Integration is more efficient Access more data Error Recovery DISADVANTAGES More time needed to set up the integration Greater understanding of the LIMS required

© Process Analysis & Automation 2005 Which integration method is best? Depends on volume of data and type of data Use Indirect if…. –low data exchange –data is only being ‘pushed’ Use Direct if…. –great level of data exchanged –Automated system runs off the data from LIMS

© Process Analysis & Automation 2005 Documentation of projects Why document ? User Requirement Specification (URS) Functional Design Specification (FDS) Factory Acceptance Tests (FATs) Site Acceptance Tests (SATs)

© Process Analysis & Automation 2005 User Requirement Specification (URS) Tell a supplier what you want Instrument choices Full methods Throughput Data handling Aspirations

© Process Analysis & Automation 2005 Functional Design Specification (FDS) Get what you want Full details of how URS will be achieved Signed agreement point

© Process Analysis & Automation 2005 Factory Acceptance Tests (FATs) See what you want exists Demonstration of an agreed set up of tests Usually down with water –Sign each test as completed

© Process Analysis & Automation 2005 Site Acceptance Tests (SATs) Receive what you want Retest some or all of the FDS test Run with real materials Sign each test as completed

© Process Analysis & Automation 2005 In summary... The key points are: Decide what you want to do very carefully Plan plan and plan again Write a detailed URS Engage a suitable integrator Follow the project Stay involved Be prepared to learn