Packaging App Group

Learn the Packaging app group's primary functions, how to use these functionalities, and how you can link different apps together within the suite. The article also includes essential configuration steps necessary for the usage of apps, alongside options for customization.
This app suite is a part of Tulip’s Composable MES for Pharma app suite.

Physical scope

The full packaging line consists of a primary packaging line, a secondary packaging line, and a boxing and labeling station. On the primary packaging line, the semifinished product (tablets) is packaged to blisters and the blisters are filled with aluminum foil. The second packaging line is connected to the primary one. On this line, the blisters are packed in cartons alongside a leaflet. The packaged finish product is put into boxes which are labeled at the end of the line.

Tulip tables used in the app suite

The main tables used by the app group are the Batch, Materials, SKU materials, and Samples tables. The SKU parameters table includes all the information required to execute the packaging process.
Corrections and exceptions are stored in a dedicated table and the navigation between apps is supported by the Stations table.

Applications in the Packaging App Group

Primary Packaging Line Changeover

This application is designed so that the operators executing the line changeover can follow work instructions and stay informed about tasks that have been done. In the first steps the user has to confirm the batch and the packaging parameters. Subsequently, on the main step or the application they can navigate to execute six different tasks. First, they need to load the blister and the aluminum foil lots on the machine. After those, the camera and the temperature could be set and tested. After the materials are loaded and the machine is set, the operators need to insert the tablets and complete the line changeover process.

Primary Packaging

Before the operator starts the primary packaging process, they need to make sure that the right materials are loaded on the machine (blisters, aluminum foil, tablets). If everything is correct, they start the machine and the app navigates to the ‘packaging in progress’ step that serves as a main navigation step in the application. The actions the operator can done during the process are loading materials on the machine, take IPC and QC samples and report downtime events. When the packaging of the selected batch is done, the operator navigates through the steps of material reconciliation and completes the procedure.

Secondary Packaging Line Changeover

This application is designed so that the operators executing the line changeover can follow work instructions and stay informed about tasks that have been done. In the first steps the user has to confirm the batch and the packaging parameters. Subsequently, on the main step or the application they can navigate to execute four different tasks. First, they need to load the leaflet and the carton lots on the machine. After those, the camera needs to be set up and tested. After the materials are loaded and the machine is set, the operators need to confirm the completion of the line changeover process.

Secondary Packaging

Before the operator starts the secondary packaging process, they need to make sure that the right materials are loaded on the machine (leaflets, cartons). If everything is correct, they start the machine and the app navigates to the ‘packaging in progress’ step that serves as a main navigation step in the application. The actions the operator can done during the process are loading materials on the machine, take IPC and QC samples and report downtime events. When the packaging of the selected batch is done, the operator navigates through the steps of material reconciliation and completes the procedure.

Line Changeover Template

The line changeover template provides a list of step templates, routing and trigger logic for app builders to use as a starting point.
Packaging Template
This template includes step groups for a variety of actions done by operator by the packaging line. As the primary and secondary packaging application this app also offers step to check materials used during the packaging process and then multiple options for sampling. These include at-line sampling, off line IPC sampling and sending samples to a QC Lab.

Material Labeling

As all the blisters are packaged in cartons and finished product is completed, the cartons are packaged in boxes. The operator are going through instructions about how to label each box and collect them on a pallet. After all the boxes are labled, the operator saves the packaged qantity and finishes the process.

Configuration and Customization

Options for connecting the app with other applications

eBR Review App of Finished Product

As all the process applications in the Composable MES for Pharma, the packaging applications are saving a lot of information as app completion data. Information about some artifacts, like comments, exceptions or the samples taken during the process are stored in Tulip Tables. The eBR review apps enable the structured review of all these artifacts.

References

• Composable MES for Pharma
• Electronic Batch Record
• Common Data Model for Pharma