LIMSzine
The following column highlights some of the underlying issues regarding
interfacing LIMS to MRP systems. For a more detailed analysis, check out
the LIMS/Letter pages (subscribers only).
Sooner or later many pharmaceutical companies consider interfacing their
Laboratory Information Management System (LIMS) with their Manufacturing
Resource Planning (MRP) system. This can be done by going through a larger
client/server network, such as Oracle7, to which both systems are connected,
or by establishing a more direct connection between the LIMS and the MRP
system, such as Beckman's Lab Manager Transaction Processing Option (TPO).
Such options also usually offer the user a choice between using either the
network or the option to connect the two systems.
By interfacing the two systems, the organization can expedite the data flow
between the lab and the manufacturing functions, streamlining data handling
and integrating data collection and reports.
Manufacturing Resource Planning (MRP)
Sometimes referred to as manufacturing systems, MRP systems are designed
to support manufacturing resource planning activities, and often represent
a key element of an organization's Computer Integrated Manufacturing (CIM)
strategy. An MRP system may provide detail production/process definition
and change control; lot control, traceability and quality management; multi-layer
master production scheduling and material planning; multiple production
techniques; and, integrated financial management.
MRP systems are often integrated with systems from Inventory, Bills of Material,
Order Entry, Capacity Planning, and Shop Floor Control. Adding the laboratory
to the loop by interfacing the MRP to the LIMS adds another layer of functionality.
The degree of integration between the LIMS and these manufacturing systems
depends entirely on the organization's CIM objectives. It often involves
the very simple, yet highly productive, application of electronically logging
samples from the MRP system onto the LIMS and then, after the sample approval
step, updating the MRP system with a disposition.
Interface Requirements
Certain functions must be accommodated to successfully interface the two
systems. If the number of printers at either the lab or manufacturing site
is few, remote printing capabilities are desirable. To minimize the need
for separate unsynchronized databases, users should have the ability to
copy files and reports from the MRP system to the LIMS using file transfer.
Finally, the interface should provide for user-written custom code on each
computer for effective communication and high performance.
MRP Integration with LIMS
The following illustrates the general manner in which a Beckman Lab Manager
LIMS is integrated with an MRP system. The TPO provides a standard, bi-directional
host interface to the LIMS, and supports a full range of transactions to
permit programmatic interaction with the LIMS, including sample log-in,
test entry and dictionary maintenance.
In the specific case of electronically logging a sample from the MRP system
to the LIMS, the organization's computer department personnel are usually
responsible for formatting the MRP sample information into the supported
TPO transaction format. This is generally accomplished with a simple custom
program. Typically, MRP systems send information such as batch or lot number,
product specification code, due date or priority, and owner or charge code
to the LIMS.
When the TPO receives a transaction, the LIMS sample login step is executed
exactly as it is when a sample is manually logged in by verifying the user,
sample, specification. It then creates a new sample in the database, automatically
attaches the tests defined in the product specification to the sample, and
assigns a sample status of "Logged, Pending Sampling" and a test
status of "Pending" to each of the attached tests.
If desired, the LIMS can send a message back to the MRP system which will
either confirm successful log-in or report an appropriate error condition.
Treatment of Product Specifications
In production environments which have integrated MRP and LIMS, product specifications
are maintained on both the MRP system and the LIMS. The MRP system maintains
a great deal of information in its product specification that has little
or no relevance to LIMS processing, just as the LIMS product specification
record maintains laboratory specific information that has little or no relevance
to the MRP system. However, there is an important subset of information
maintained in these records which must be shared and synchronized, such
as required tests, specification limits and targets, and revision number
and date.
LIMS installations have solved this problem of synchronization by identifying
the "owner" of the product specifications. Some organizations
use the MRP and its management for creating, updating and deleting product
specifications. Others have selected the laboratory and the LIMS as the
owner. In either case, MRP and LIMS integration requires that the owner
system notify the dependent system with updated product specifications either
periodically or upon demand. This process can be completely automated using
a TPO-type connection.
Summary
When an organization grows, the need to connect various information systems
increases. Numerous vendors offer different solutions for interfacing LIMS
and MRP systems. In fact, SAP, which currently markets one such interface
option, will soon offer a more sophisticated online interface that allows
direct commands between the different systems.
Companies such as Ciba-Geigy, UpJohn, Hoffmann-La Roche and ICI Americas
have all successfully interfaced their LIMS and manufacturing systems with
various levels of interaction. Such an interface allows various groups within
the organizations to work independently or collectively as the need arises.
By efficiently implementing a LIMS/MRP interface, organizations are able
to maximize their investment in both hardware (terminals and printers) and
software (LIMS and MRP).