Brillig Systems is dedicated to furthering the knowledge and practice of Automation Project Management. Project management professionals have a plethora of materials, newsletters and online forums to discuss project management topics. Most of them are exceptional for fundamental project management. However, none of them focus on automation project management specifically. Perhaps the greatest step forward for manufacturing has been the acceptance and implementation of automation. This newsletter will discuss topics relevant to managing automation and its implementation.

We love what we’re doing and we welcome any questions you might have. Please contact us at contact@brilligsys.com if you have a question or would like to know more about any of the topics presented here.

Metrics for Successful Automation Project Management

Most automation engineers spend their days controlling manufacturing processes, but spend little or no time controlling their project schedule and budget. This is not surprising as they have little or no involvement in budget reviews or project management activities, other than the schedule, for much of the duration of the project. However, when the project is suddenly over budget, automation engineers have more involvement in finances than they want, and most of that involvement is not good. They are likely to be dragged through the dirt. But if the

project has been successful and the control system does what it is supposed to do, Automation Engineers get little positive feedback or reward for this achievement. Such is the plight of the engineer. …read more

Process Automation Round Table (PAR)

The Pharmaceutical Automation Roundtable (PAR) is a group of automation leaders from the biotech and pharmaceutical industries. This group is a who’s who in the industry and collectively shapes the course for successful operations. The focus of the group is to bring value to the industry by collectively sharing knowledge and data that each representative and their company have experienced.

Recently, Scott Kendra hosted PAR’s annual roundtable at Amgen in Rhode Island. This year’s attendees were Amgen, Biogen Idec, Genentech, Genmab, Genzyme, Glaxo, Lilly, Lonza, Novo Nordisk, Pfizer, Schering-Plough, and Wyeth. They shared non-competitive information using guidelines of the Pharmaceutical Research and Manufacturers of America (PhRMA) Group.

The keynote presentation of this PAR event was a blind benchmarking exercise presented by Brillig Systems’ own David Adler. This benchmarking exercise was conducted with all individual information held in the strictest confidentiality according to the American Productivity and Quality Center’s (APQC) “The Benchmarking Code of Conduct.” The data was compiled, analyzed and placed into a summary report for the audience.

This summary report contains: 1) the average level of technology implemented, ranging from field instrumentation, to data analysis tools for automation, 2) the average cost of automation projects, the project factors impacting cost, and the facilities characteristics that impact cost, and 3) the financial benefits of automating new and retrofitted facilities, and the characteristics of those facilities with the highest benefits.

This study has identified the golden projects that are significantly better in achieving best automation project results. The study revealed the most significant factors on cost variability that are common among those projects. It also showed that there were common key factors present in every successful project. Perhaps more importantly though, the study identified the common factors among failed projects.

Knowing and implementing those success factors into your projects gives an unquestioned advantage. Avoiding those common factors that lead to project failure could be even more beneficial. Moving your project delivery strategy in line with the golden projects and away from the failed projects would certainly give you the peace of mind that comes from knowing that you are doing the right things.

If you didn’t participate in the PAR benchmarking study, don’t panic. It is still possible to enjoy the benefits by participating in the ongoing portion of the study. Brillig Systems can use the summary data and analysis for review of your individual project. This could help you understand and improve your automation delivery cost and drive business processes in automation to achieve them. Brillig Systems has the unique ability to audit, interpret, and make critical recommendations. Send us an email or call our main office for more details about how to get involved.

Employee Spotlight on Buffy Linville

Every month we spotlight a Brillig employee who exemplifies our values, is committed to our clients, and is consistently providing value to all those involved.

This month we spotlight Buffy Linville. Buffy has been a Project Controller with Brillig Systems since June of 2005. She has been an instrumental part of the Brillig Indianapolis operations and continuously exceeds the expectations of our clients. Her people skills coupled with her professional skills and accomplishments, put her at the top of her field. Buffy has a Mechanical Engineering Technology degree from

Purdue University and recently earned her CAPM (Certified Associates in Project Management) from the Project Management Institute. Congratulations on her achievement.

Buffy and her husband Nathan reside in Acton, Indiana where they enjoy spending time with their children Ethan (8) and Grace (5). They spend much of that time training in Tae Kwon Do as a family. Buffy, who has a brown belt, also teaches a preschool course at the dojo. Great work Buffy!

Project Profile

Projects are fun, challenging and expand our experiences with each one. We try to profile projects from time to time to share with others some of the interesting things automation project managers are involved in.

Brillig Systems has a stellar record of success managing large automation projects. This success tends to build long-term relationships with our clients. Our current project in Puerto Rico for an international biotechnology company is a great example. Now in the commissioning phase, this project is the third in succession for this client since 2003.

The current project began in 2006 when Brillig was engaged, through our work with a multinational engineering firm, to help plan a major expansion to a facility we had just completed. Expansion of an existing facility is always difficult, but expanding a facility in a regulated industry presents even more challenges. Protection of the system’s validated state, document and software change control, integration of processes and configuration management are just a few of the challenges.

In the years since the project’s beginning, Brillig has provided the overall automation project management as well as several key automation specialists to design, implement and deliver the automation system for the facility. Currently the design and implementation phases of the project have been completed on schedule and commissioning is well underway.

LinkedIn Automation Project Management Group

Since our last newsletter, the group has discussed the evaluation of projects in much more detail. This builds on the previous discussions of project benefits. The discussion also focused on estimation and justification.

For management to agree to proceed we need to demonstrate a sufficient return on the investment (payback). So now it is time to estimate the cost associated to the project. Estimation is as old as doing projects and several tools are available. Some tools are available to format your data, while other tools perform item estimates. The group discussed the tools they are using and the method used for project justification. Then the topic moved to scope determination and refinement that is needed after the project is justified.

There is never a lack of topics for debate. The group engaged around the Automation Competency model and Automation certification. Of course there was plenty of input on the state of the global economy with some very interesting opinions on the subject.

Join the Automation Project Management Group here: LinkedIn

Automation Project Management Seminars

Brillig Systems is announcing the release of their “Successful Project Management Seminar” schedule for 2009. Brillig will be sharing key project management techniques and methodologies used to deliver successful projects in multiple industries. Don’t miss the opportunity to learn from some of the leading project managers in industry today.

These sessions will be packed with relevant, real-world information for new and veteran project managers alike. Locations are filling up, so register early to guarantee your spot. Visit the Brillig website and click on training to register or to get more details about our other training seminars. Information for the next seminar is below:

When: March 20, 2009

Where: Greenville, SC Brillig Corporate Office

Time: 11:00 to 1:00 Lunch and Learn

The Jabberwocky Challenge

As project managers, we are inherently problem solvers. This is a section dedicated to having some fun with a challenge. The scenario below represents a real situation that an automation project manager might encounter.

Scenario: You are the automation project manager for a new widget manufacturing plant. You receive a change request that will affect the

schedule. With an approved change, you are asked to deliver a cost and schedule change estimate with a confidence level of over 95%. You interview the subject matter experts and you receive an estimate of 3 months and an estimate of 12 months. Historically, it has taken 8 months to deliver this additional scope on other projects. Assuming both experts are qualified, what would be your response to management as to the time it would take to deliver the change assuming no additional constraints?

The best response is:
A: Eleven months.
B: Eight months.
C: There is not enough information to make a reasonable estimate.
D: Nine months.

Send us your answer and all winners will be posted in next month’s newsletter. Good Luck!

Answer to Last Jabberwocky Challenge

The best answer to the last challenge was B. Congratulations to Vipul Tilati for being the first to provide the correct answer!

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