Revolutionizing Line Clearance with Smart Clearance: A Breakthrough in Operational Efficiency

Line Clearance is a crucial procedure in the life sciences industry to ensure that equipment and work areas are devoid of products, documents, and residual materials. This process helps operators prepare for the next scheduled production run and is particularly important to prevent cross-contamination between different production batches or between different products manufactured on the same line.?

The Line Clearance process typically involves different phases:

1. Clearing: Remove Residual Products and Packaging: All residues from the recently produced product, including powders, tablets, liquids, and packaging materials such as labels and boxes, are removed from the line.?
2. Cleaning of Equipment and Environment: Thoroughly clean the equipment and surrounding area to remove all traces of the previous product.
3. Checking: Conduct a detailed visual inspection to ensure no visible residues remain from the previous batch.?
4. Documenting: Meticulously document each stage of the cleaning process for traceability and audit purposes.

Challenges in Line Clearance

In the context of challenges related to line clearance, the increasing frequency of weekly changeovers — with over 50% of pharmaceutical companies handling 5 to 20 changeovers each week — makes line clearance efficiency critical. The time required for these processes can vary significantly, from 40 to 60 minutes for the same product and size to up to 180 minutes for new products. Each process typically involves 2 to 4 people, significantly impacting overall production time and costs.?

Introducing Smart Clearance

Antares Vision Group's Smart Clearance is an automated solution designed to digitalize and streamline the line-clearance process. This innovative solution combines a software platform that can be powered by AI algorithms with hardware to be installed on the line, such as control cameras, to:

• Reduce changeover times
• Eliminate paper-based operations
• Enhance security
• Ensure compliance with proven record of executed activities

How Smart Clearance Works

The Diamind Factory | Smart Clearance module integrates cameras to capture images at critical detection points, which are then processed by AI-powered software to detect foreign objects. When an anomaly is detected, an alert is flagged for the operator, who is guided to resolve the issue step-by-step. This approach ensures that the line-clearance process is thorough and efficient, significantly reducing the risk of errors.

Benefits of Smart Clearance

• Efficiency: Enhances existing line investments, secures the changeover process, reduces inspection times, and increases operational efficiency and line availability, leading to a higher return on investment (ROI).
• Digital Transformation: Supports the digitalization of Industry 4.0 frameworks, improves quality control, automates report collection and storage for complete traceability, and ensures compliance with GMP regulations and 21 CFR Part 11.
• Health and Safety: Reduces risks to operators by automating and streamlining the clearance process.

Technology and Design Features

Smart Clearance is part of Diamind Factory's Quality module and leverages AI and advanced camera technology to automate line-clearance operations.

Key features include:

• AI Detection Tool: Trained to recognize an empty line, the tool captures images and detects foreign objects in real time.
• Activity Records: Maintains a record of all activities performed to provide evidence to regulatory authorities in case of a complaint.
• Automated Alerts: When a foreign object is detected, the system alerts the operator to take corrective action.
• Comprehensive Guidance: The system guides operators through the entire process, ensuring thorough and efficient clearance.

Conclusion

Antares Vision Group's Smart Clearance solution represents a significant advancement in line-clearance technology. It offers faster, more efficient processes and enhanced compliance with regulatory standards.

By integrating AI and digitalization into the line-clearance process, Smart Clearance improves operational efficiency and increases line availability and safety.

Visit our website to learn more about this innovative solution, and contact us to transform your operations.