List of Custom Software written by Dr. Serdakowski for a Major Biotech Corporation

AutoSoft Systems

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Commercial & custom multi-user computer software for a variety of applications including performance metrics, statistical analysis, data extraction and merger from multiple large databases, computer simulation and management information systems. Founded in 1982.

We know Excel! Whenever possible, Excel is the user interface, VBA is the programming language, ODBC connects to the database of your choice.

Pharmaceutical & Biotech

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List of Custom Software written by Dr. Serdakowski for a Major Biotech Corporation

This page lists the many software applications written and maintained by Joe Serdakowski, Ph.D., P.E., M.B.A. in use at a $20+Billion annual sales Biotech firm with manufacturing on 3 continents (code-named “Acme Pharmaceuticals”). This list represents an ongoing effort of 6 days a month for over 5 years. (Last updated May 12, 2019).

Joe supports initiatives at Corporate Headquarters and 6 manufacturing facilities. Joe's role is to improve information flow and thus assist the users of his software work more efficiently with better information & "GET HOME ON TIME". 😊

Joe teaches a series of Excel and VBA (Visual Basic for Applications) training courses. Joe welcomes the opportunity to teach these courses at other companies.

Acme has provided Joe with 4 computers:

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His primary laptop computer

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A Server used to update the list of reports below and automatically send out email notifications

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A Desktop "Mini-Server" that allows Joe and other selected users to RDP (Remote Desktop Protocol) into this Server using a Pulse Secure connection. Because of security and firewall considerations, certain operations take much longer if you are off site. By using this RDP connection, these operations execute as fast as they would if the user were on site. If you periodically log in from home and are burdened by sluggish performance, contact Joe for access to this "Mini-Server" to improve productivity.

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A "legacy" lap top computer that continues to support older computers at Acme. This computer is also used to perform lengthy calculations in support of Joe's efforts.

AutoSoft's Solutions Paradigm

It is important to note that Joe has been developing custom applications and reports since 1981 and at Acme since 1999. Joe has had a continuous presence at Acme since 2005. He has acquired intimate knowledge about several of Acme's corporate databases, including Maximo, Trackwise, StarLIMS, Pi Historian and the Document Management Database. He has a proven track record of delivering solutions for very low costs on very short time tables that exceed expectations. He provides 24x7x365 support and typically resolves issues in less than 1 day. Anyone who argues against his paradigm for application development is simply ignoring the facts and 14 years of success. Joe's paradigm is constantly evolving and employing the newest tools and features, but only when there are derived benefits. Joe's paradigm will continue to be the most cost-effective platform to develop and maintain a large swath of current and future requirements. Joe believes that it is in major corporations’ best interest to exploit this paradigm and formally recognize it and promote it as one of several paradigms for custom software development. Joe's long-term commitment to his work is strong and he is eager to work with decision makers at other major corporations in whatever capacity is best for the corporation, whether that be separate POs for each project, a blanket PO with a formal contract and receiving direction from one source, or as an employee and part of a team that develops and supports this paradigm.

Microsoft Excel is used as the user interface. VBA (Visual Basic for Applications) is the programming language. Various back-end databases are employed (Azure, SQL Server, Oracle, Progress, AWS DynamoDB, Access). It is a common misconception that Excel is not a suitable framework upon which to build "industrial strength" multi-user applications. This is true for Excel workbooks that are composed and managed by most casual users. HOWEVER, there are a number of features that when employed provide the necessary structure to exceed even the most rigid corporate guidelines for security (see WeKnowExcel.com/ExcelSecurity.htm). Several of Joe’s tools at Acme have been validated.

AutoSoft's Body of Work at Acme

The following is a list of many of Joe's programs, past and present.

Work Order Administration (WOA) Software

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SQDIP (Safety, Quality, Delivery, Inventory, Production), Work Center Board and Innovations suite. This collection of integrated applications is used by WOA, Mechanical Maintenance and Facilities. In use since January 1, 2016. Since April 1, 2017 used by 135 different users. A complete Change Log has recorded over 78,000 separate transactions during that time span. Over 3,200 hours/year have been saved since April 1, 2017. The underlying Access database is backed up hourly to prevent data loss. Upon creation of a SQDIP, the App automatically emails the assignee with notification of the issue. The assignee can edit and update the issue directly from the email. The suite includes the following applications:

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SQDIP.xlsm - SQDIP issues and Innovations editor. Upon opening provides the user with a dashboard listing the following metrics for both site and the individual user:

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SQDIP Open Records with no due date

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SQDIP overdue records

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SQDIP completed or cancelled records with no completed date

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Delivery SQDIP completed with no Flow Interrupter Code

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SQDIP completed with blank Extended Hours saved

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SQDIP open records w/ Date Due < 7 days

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Work Center Board.xlsm - Work Center Board Issues and Overview Email generator. The Overview Email is a "one-click" comprehensive Facilities Status Report, fully rich HTML format, with varying colors and fonts to highlight key issues and recent changes. The email is sent to over 60 people.

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SQDIP and Work Center Board.xlsm - SQDIP issues, Work Center Board issues, Manager Notes and Innovations editor and Work Center Board Overview Email generator

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SQDIP Metrics - Generates a 9 slide PowerPoint document that includes the following:

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High frequency Job Plan repeats

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SQDIP Issues count sorted by Department, Shift and SQDIP type

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Common Productivity Flow Interrupters Sorted by Shift

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Common Delivery Reason Codes Sorted by Shift

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SQDIP Assignment Completion Metrics - Days from entered to completed and # of current open

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Overdue SQDIP records

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SQDIP Exceptions

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SQDIP Cycle Counter

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Allows user to select a subset of SQDIP issues over a specified time period and provides a dashboard including the following metrics trending with time

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Open and closed count

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Cycle time

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Time Lost

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Hours saved

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Percent completed in # of days

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SQDIP Weekly Exception Report - All users with one or more exceptions receive a weekly email asking them to resolve the exceptions. The assignee can edit and update the issue directly from the email. The exceptions include:

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SQDIP Due Date is within 7 days

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SQDIP status is 'Completed' or 'Cancelled' and completed date is blank.

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SQDIP status is 'Completed' and Flow Interrupter code is blank for either 'Delivery' or all other types.

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SQDIP status is 'Completed' and Extended Hours saved is blank (must be either a positive number or ZERO).

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Root Cause Code is 'Other.' and Comments are blank.

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Weekly WOA Snapshot - Generates in less than 2 minutes with a few mouse clicks a weekly email to 30+ recipients, providing dashboards on the following metrics. The tables are embedded into the body of the email.

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PMs Past Target Completion Date by Building and Level (not including OFSR)

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Weekly Work Order snapshot on 38 different metrics for the last 4 weeks

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CM and GM work order count (table and charts) by 9 craft "buckets" and 3 age "buckets" (<30 days, 30-90 days, > 90 days)

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Backlog by Craft, work orders over 90 days of age, trended over the last 13 weeks.

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Average work order backlog by craft over the last 8 weeks (table and chart)

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Level 1 CMs that are past the target completion date.

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Work Order Scheduling "Schedule Helper" - This is a suite of apps that work together to assist the work order scheduler/planner in his/her duties. Very tight integration with Maximo, both read and write. Scheduler clicks on a work order then clicks on a day to add it to the schedule. The committed vs available person hours to complete the task list each day is presented. Several cautionary messages are presented if a work order is in danger of not being completed on the target completion date. There is a supplemental Access database (daily backups) supporting this tool. This app was commissioned because other options did not fulfill WOA's requirements

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Schedule_Saver - an Excel XLSA "Add-in" that provides the user with a number of custom functions by pressing the "F" keys:

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F4 - Build a Snap Shot of the schedule

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F5 - Updates Work Orders on the Detail Sheet from the Report sheet

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F6 - Updates available hours on the Detail sheet

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F7 - Updates Work Order status from Maximo

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F8 - Generates a Maximo Loader file

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F10 - Saves entire Detail sheet to database

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F11 - Updates Ready Work

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F12 - Attempts to repair the database

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Maximo_Query - The scheduler/planner opens this file to start the process. A one-time configuration for each user provides a list of work orders to be scheduled. The generated scheduling folder opens with two windows, one window listing all work orders, the second is a calendar. The user simply clicks on a work order, then clicks on a date to schedule it. The user then assigns a shift. The available technician hours are calculated based on the labor hours in each work order. The scheduler/planner can add colored background and fonts to highlight instructions.

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Staffing Editor - Tracks the technicians working each shift. The user can record time off and added coverage for any technician on any day so that an accurate total of available technician hours is calculated for each day.

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Schedule Reviewer - User can generate a list of scheduled work orders filtered by date range, location and labor group. The colored fonts and background recorded by the scheduler/planner are reflected in the report.

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Work Order Status Updater - synchronizes the Maximo and Schedule Helper databases. Updates nightly.

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Work Order Schedule Adherence Tool. Queries Maximo, looks at actual vs target work order completion dates and schedule changes. In the case of a work order closing beyond the target date, prompts the associated planner to identify the root cause as to why the work order was late. Regarding schedule changes, prompts the associated planner to identify the root cause for the change. There are two components to this:

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AutoSAT - user interface to review and assign root causes to late and rescheduled work orders. Each user can control what subset of work orders are their responsibility and add/edit root causes. Synchronizes with Maximo nightly.

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Summary Metrics - provides a dashboard of metrics

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Maximo-LMS (Learning Management System) Reconciliation Utility - Takes a report from the LMS which lists all personnel trained in Maximo access and compares that to the current Maximo access for each person, identifying if anyone has expired training. Great auditing tool.

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Job Plan Duration Tool - Compares actual labor hours recorded against Job Plans to target labor hours. Provides dashboard illustrating how each Craft group is performing. Assist planners in their review of Job Plans to align targets with actuals. Allows planners to drill down into each craft for each work order on each job plan to see actuals.

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Many Maximo Reports

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Asset_Calibration_Ranges - lists over 4,000 Asset Calibration Ranges. - updates nightly

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Maximo_Asset_Query - lists properties of over 44,000 Assets - updates nightly

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Maximo_CC_CE_Query - lists properties of open work orders of Work Type - "CC" or "CE". This utility has a supplemental Access database that allows the users to record and save comments pertaining to each work order for others to view. A historical log is maintained so one can view the changes made to the comments for each work order

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Maximo_JP_Waiting_Query - lists Job Plans that are in selected Statuses and emails the Owner and/or the QA Assignee if the Job Plan has been in the specified Status beyond a specified period of time - updates nightly. On April 15, 2019 the following user defined criteria have been set:

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If the Job Plan has been one of the specified Statuses for 5 or more days, notify the QA Assignee with an email. The specified Statuses are 'WQA' and 'WQAP'.

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If the Job Plan has been one of the specified Statuses for 10 or more days, notify the Owner with an email. The specified Statuses are 'JPWA2R','JPWA2RP','JPWAR','WJPO','JPO2','WJPI','JPO2P','WJPOP' and 'JPWARP'.

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Maximo_Labor_Groups_Query - Shows all Labor Groups, their members and default assignees - updates nightly. On April 15, 2019 there were 680 people listed in 431 Labor Groups.

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Maximo_Location_Query - Lists all Maximo Locations and 14 key properties of each location - updates nightly.

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Maximo_PM_Status_8 - Lists the status of PM that are due in the current month or are overdue. Provides a Metrics Dashboard to show percent completed based on Labor Group Default Assignee. User selects option and updates. Requires Oracle ODBC drivers installation. There are 4 options:

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Manufacturing PMs

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QA PMs

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Manufacturing with MM Crafts and Labor Groups

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All Open Work Orders with one of the three filters above.

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Maximo_PMM_Query - Lists all PMM work orders that are in one of many statuses picked by the user from a list of possible work order statuses. A total of 15 properties of each work order are listed. There are 41 possible work order statuses, 29 statuses are currently selected resulting in 59 work orders (April 17, 2019). Additionally, if any Level 1 work order is due within 14 days, the associated Primary, Secondary and Tertiary Planner receive an email. The email is repeated if the work order is due within 7 days. The email is sent out daily if a work order is overdue. There is a "Comments" field for each work order where users can record comments about each work order. These comments are saved in an Access database. The user can then select a work order and review the history of the comments. - updates nightly.

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Maximo_WATTCH_Query - Lists all work orders in the WATTCH status. Includes 11 different work order properties, including documents stored in Maximo that are associated with each work order. A link is provided to open a document directly. Accommodates the fact that a single work order may have multiple attached documents. Provides a visual metric if the work order exceeds a specified time in the WATTCH status. There is a "Comments" field for each work order where users can record comments about each work order. These comments are saved in an Access database. The user can then select a work order and review the history of the comments. - updates nightly.

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Maximo_WRECON_Query - lists all work orders in WRECON status. Emails the responsible party every Monday if a work order is in WRECON status for 5 or more days. Supplemental database allows WOA personnel to record notes specific to each work order.

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Open_WO_Report_Today - Lists all open work orders - updates nightly.

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Maximo Data Integrity Report - performs a series of queries that looks for over 50 different possible data inconsistencies in Maximo. One can drill into any issue to its root cause. Very powerful. Can be quickly reconfigured to support any Maximo facility

Maintenance

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Spend Analysis Version 17 - Allows the user to analyze spare parts consumption - updates weekly

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Maximo Z-Number Editing Tool (ZeeNET) - Maximo manages creating and revising Z-Numbers (spare parts) using AAE work orders. This tool tracks all the key properties and documents and manages the AAE work order process. There is a supplemental back-end Access database and the tool is fully multi-user. No data is stored in the front-end Excel document which is stored "read-only" on the network. There is a web-based tool developed at Acme that provides this same function. However, personnel have found this option not adequate for their requirements. The ZeeNET tool has been modeled after a prototype and fulfills all requirements.

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Notification Emailer - This tool performs a query into the Maximo Database, returning records that are within 21 days of, or beyond the deadline for owner action. The tool will send out emails to each owner, clustering all records for each owner into one email. Records will be included in the email if the deadline is 21, 14, 4,3,2,1,0 days away or if the deadline has passed.

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Maximo Mean Time Between Maintenance - This tool looks at all work orders in Maximo®, and allows the user to slice and dice the data by 20 different parameters (i.e. Start Date, Work Type, Site, System Description,….). Once the user defines the subset that is to be analyzed, a stand-alone workbook containing all of the pertinent records is generated. In addition to a detailed listing of all workorders matching the filter criteria, one can perform Pareto analysis by Site, Building, System and Sub-System based on # of Events or $$$ spent. Pareto charts can also be generated.

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Maximo Mean Time Between Failure - Let's face it. Equipment breaks. Often at the worst possible time. Some equipment breaks more often than others. Maximo® has stored in it a huge treasure-trove of information. Getting it out sometimes seems more difficult than getting gold out of sea water. AutoSoft's Mean Time Between Failure tool calculates just that for all equipment stored in Maximo. This is a pre-compiled program, meaning the program pre-processes the necessary information overnight, resulting in a quick and easy user interface that gets you the answers quick

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Maximo Late PM Maintenance Notification Tool - This tool scans the Maximo database and culls out PM workorders that are overdue or soon to be overdue. The owner of each work order is identified, and an email is sent to each owner warning him/her. This utility can be set up to run automatically at whatever frequency is desired.

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Maximo Asset Spare Parts Email Reminder - This tool performs a query into the Maximo Database, returning records that are within 21 days of, or beyond the deadline for owner action. The tool will send out emails to each owner, clustering all records for each owner into one email. Records will be included in the email if the deadline is 21, 14, 4,3,2,1,0 days away or if the deadline has passed.

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Maximo Data Scrubber - This program combs through the Maximo database and isolates 5 defined exceptions and 2 specific database changes. It automatically sends emails to the system owners, notifying them of the exceptions and "encouraging" them to make corrections. The number of exceptions are trended with time so that progress can be tracked.

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Maximo Subsystem Analysis Workbook - The program assists system owners in optimizing Preventative Maintenance frequencies and costs.

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Maximo Data Dictionary Generator - The Maximo database comprises approximately 400 tables and views and in excess of 14,000 total fields. This tool provides lists of the tables and associated fields, as well as "clones" each table into a stand-alone Excel workbook putting the entire Maximo table structure and content at your fingertips! This tool is a great time saver for any programmer looking to generates reports out of Maximo

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Equipment Engineering KPI (Key Performance Indicators) - The report updates nightly.

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AutoDispatchLog - Multi-user Excel front end, Access backend database to track maintenance issues that occurred.

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AutoCriticalUpdates- identifies the count of followup work orders that had to be executed after the completion of a job plan work order.

F&E (Facilities & Engineering) Infrastructure Operations

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PPM (Project Portfolio Manager) - This multi-user tool manages resources, schedules and cash flows for the portfolio of capital construction projects at 3 major manufacturing facilities. The PPM solves the vexing problem of managing a slew of projects without the overhead of a long learning curve associated with other project portfolio management software programs. Integration with corporate ERP systems eliminates double entry of purchase order and invoice information for cash flow and budget reporting. Each user is presented with a list of all projects where he/she has been assigned tasks and can verify or modify the estimated and actual time required for each project on a weekly basis. The Project Managers have total visibility to all resources, budgets, cash flows and schedules and can quickly adjust to changes. Resource managers can level load resources and quickly recognize and eliminate future "pinch points." This tool has been continuous use at Acme at as many as 3 sites since 2005. Acme "alumni" have employed this tool at 2 other pharma companies. A supercharged version of this tool controls over $1 Billion in construction projects at New Line Structures, one of the 7 largest construction management firms in New York City. For several years a companion app, the TransMaster, used at two sites, provided PO line and Expense visibility, importing data from SAP.

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Document Management Database Audit Trail Detail Report -a flexible search utility into the Document Management database. Upon opening, the default behavior is to generate a list of all open work flows. The user can also query the database for any subset of documents, and generate a detailed report for any document that includes:

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Header information

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Open Workflow items

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User Acknowledgements

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Change Status

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Other Activity

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AutoPlaybook - Outage planning is time consuming. One or more Microsoft Project files are updated frequently to schedule all of the events associated with an Outage. The AutoPlaybook reads from the Microsoft Project file(s) and generates a series of PDF files. 1-10 files are generated for each day. The PDF files have a floor plan of the building(s) in outage, with color coding to indicate the gowning level and work being performed in each area. Also, a comprehensive list of all work is included in each file. The AutoPlaybook then performs daily updates, naming and placing copies of "today's" files so that they can be displayed on video screens around the company to keep all informed. AutoPlaybook has supported 3 outages at two facilities (2015, 2016, 2018).

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PM Forecast Reporting - these tools, one version for each of 5 sites, allows the user to forecast PM work orders with a 2 year look ahead - updates weekly. Predicts meter-based PMs as a function of the future production schedule (some products uses certain equipment more, so the meter moves at varying rate depending upon the product being made.

StarLIMS and PI Historian Data Extraction Tools

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Asset Calibration Ranges - This report lists all the calibration parameters for all calibrated assets and greatly simplified the task of verifying that the span of each calibration exceeded the minimum and maximum operating conditions. Provided detailed metrics as to the progress of each system owner. Managed over 7,300 calibrations.

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AutoEvents - Using PI Historian Process Data to Optimize Preventive Maintenance - This App won Corporate recognition and an award! Preventive Maintenance is a necessary function of every manufacturing facility. How much is too much? How much is too little? AutoSoft Systems has developed a suite of software tools that can be easily customized to assist in this decision at a variety of manufacturing facilities. Here is how it works: A large Bioprocess facility has thousands of diaphragm valves. Diaphragms wear out and need to be periodically replaced before they fail. The site has a well-established process for periodically shutting down each system for a "Lock-Out Tag-Out" (LOTO) where all of the diaphragms in the valves are replaced. They rarely if ever have a diaphragm failure, so they do not want to mess with success. They do know, however, that not every valve experiences the same amount of usage. They would like to be able to determine the amount of wear and tear on each valve and extend the replacement cycle on those valves that see lighter duty. Diaphragms experience wear and tear when they are opened and closed and when they are subject to elevated temperatures. AutoSoft Systems extracted wear and tear information about each valve from the PI Historian system and provided engineers with a slick, quick and easy to use interface to determine the wear and tear on each valve, and offer recommendations on the maintenance frequency. This process could be extended to all devices subject to repetitive motion.

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Global Water Committee Monthly Report This app generates a monthly report summarizing the status of WFI and PUR water systems at 6 different manufacturing facilities.

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The app collects over 4 Million data points from 103 PI tags at the 6 different facilities and compiles the data into a 3-dimensional dashboard. By right-clicking a value, the user can see a Histogram on the monthly performance of any PI tag as well as a list of all excursions. The 3-D dashboard tracks:

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Event Count Above Alert Limit

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Total Sample Count

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Hours Above Alert Limit

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Sample Count Above Alert Limit

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Hours Above Action Limit

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Sample Count Above Action Limit

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Intervention Free Operation

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The StarLIMS database is also scanned, identifying over 5,000 data points each month, and track a variety of exceptions in the LIMS data, reporting on the count each month.

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The end result is a Microsoft Word document which then the system owner can add some clarifying comments and distribute to key stakeholders around the corporation. Joe has been preparing this report every month since January, 2009.

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WFI Trace Metals Analysis - Slices and dices StarLIMS WFI trace metal test results (Cr, Fe, Mn, Mo, Ni) by Site, building, Room and Sample point. Provided very comprehensive and colorized dashboard to compare and contrast results. Assigned a numeric "grade" on a scale from 0-100 to allow for quantitative valuations of each sample point. Identified potential trouble spots.

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WFI and PUR Water LIMS Query Tool - This app provides a quick report for users to extract StarLIMS data on WFI and PUR water. The "Advanced" option allows the user to extract information about any and all data in the StarLIMS database. Used around the Acme since 2013 with minor updates.

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MATRIX LIMS Query Tool - a comprehensive LIMS Query tool allowing the user to filter on 48 different StarLIMS data fields. Provides results as a table, Histogram and Statistical Process Control Chart.

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Generic PI Data Extractor - a simple Query tool allowing the user to enter a single PI tag and date range. Provides results as a table, Histogram and Statistical Process Control Chart.

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PI Reporter - A suite of custom tools that allows the user to perform the following analysis. My intimate knowledge of Chemical Engineering principles, The PI Historian database, Excel and VBA allows me to quickly and economically build custom models of this type.

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WFI Tank Mass Balance

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WFI Still 1 Production

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WFI Still 2 Production

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Neutralization Volume

Financial Applications

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SWEET - F&E Expense Budgeting and Tracking. Imports Purchase Order and Expense data from SAP. Compares Budget, Allocation and Actual expenses. Can slice and dice the data by SAP Account, Vendor, Hyperion Account, Accounting Group and Accounting Sub-Group. Very quick, powerful and intuitive. Many data validation features included. In its second year of use.

Quality Applications

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Department Trackwise Reports - These reports generate daily emails to a designated list. The Trackwise contents are filtered to only include those records that are pertinent to each department. Additionally, if a CAPA Action is impending or overdue, the CAPA Action Owner receives an email. This is not a trivial task because the CAPA Action Owner field in Trackwise does not have data validation, so users enter the strangest things. I have a complicated algorithm to determine the CAPA Action Owner. If the algorithm fails, I receive an email and can then improve the algorithm. In use by 5 different departments at 3 sites.

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The Daily report lists the following:

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NCs

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CAPA Actions

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CCs

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ARAs

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CAPAs

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EVs

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PMAs

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Annual To Date and Prior Years' Performance Metrics

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AutoReporter Utility - This tool queried the Trackwise database and builds a very comprehensive PowerPoint slide deck on quarterly performance around the corporation. The framework has been built to also query Maximo and other corporate databases. Huge time saver.

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Site-Wide NC Trending program - a fully validated application.

Cross-Functional Applications

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The MATRIX {Corporate-Wide} - This tool is a universal search and retrieval tool that can simultaneously search multiple corporate databases for key words. Results are achieved in seconds! Potential annual times savings can easily exceed 1 million dollars. Corporate databases are good at getting information into them but leave much to be desired when you need to find something. Typically, you must search one database at a time. The MATRIX does it all for you.

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The MATRIX is currently being hosted at that 10 different network locations.

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The following databases are now searchable:

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Document Management Database

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Maximo

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Assets

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Job Plans

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Spare Parts

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Work Orders

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PMs

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Job Plan Tasks

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Locations

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Trackwise

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NCs

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CAPAs

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CCMS

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CCPRD

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Trackwise - Maximo Data Synchronization - Non-conformances continue to exist despite everyone's best efforts. Accurate and complete documentation of each and every NC is of paramount performance. Some NCs are related to process equipment and/or have a "Machinery" root cause classification. Text entry fields in Trackwise allow the NC owner to record the equipment and the system associated with equipment and/or machinery related NCs. There is no mechanism in Trackwise to validate that the equipment or system entered is indeed a valid Maximo entry. AutoSoft can!

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Trackwise - Maximo combined report - Don't you just love it. Corporations today have software tools for all different functions, however getting them to talk to each other is difficult to say the least. I was asked by Acme to develop one report that would automatically extract data from both the Maximo® and Trackwise® databases. I delivered the finished product in less than one hour.

Manufacturing Support

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Chromatography Column Scheduling and PM Cost Forecasting - This single app looks at the High Level Production Schedule, the current state of over a dozen chromatography columns and closed Maximo work orders. The app determines when Chromatography column packing schedule to minimize the number of repackings and production schedule interruptions, provides date ranges for column changeovers, calculates column changeover costs for the year. Very powerful and difficult to program.

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Manufacturing Workforce Models - I have worked on several variants of this tool since 2010. In all cases Acme system owners built a complicated Excel workbook or series of workbooks that eventually became cumbersome and difficult to use. At that point I was brought into the development cycle to rebuild the tool to make it workable again. The current model accommodates up to 20 different products in a multi-product facility with varying run rate and labor requirements for each product.

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AutoMedia - The cost of a storage bag exceeds the cost of the media inside it in many cases. SOP requires that full batches of media be prepared. With a multi-product facility, often not all of the media is consumed before it expires. AutoMedia looks at the High Level Production Schedule, looks at production constraints (e.g. how many media batches can be produced per shift) and calculates when the media must be produced and what fraction of the media will be consumed before expiring therefore determining how much media should be packaged and how much could be discarded. Potential annual savings is $400,000.

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AutoServices - scheduling aid for storage vessel maintenance and Media/Buffer tasks.

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AutoSAM - Schedule Adherence for Manufacturing

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AutoMAC - Calculated the Maximum Allowable Carryover contamination level during change overs between products.

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AMPP Visualizer Program - This program takes a Werum scheduling export file and visualizes when the various pieces of equipment listed in the file are scheduled to be busy. The Gantt chart is shaded red whenever the equipment on that line is scheduled to be in use.

Utilities

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Training Assistant Program - an app that builds a decision tree. Used to build individual training requirements based on the tasks to be performed. Very powerful.

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Server Maintenance Utilities - these are used by Joe Serdakowski to manage the Acme server with minimum amount of work. These tools send emails and if a critical issue is detected, a text message to alert Joe of issues before they affect server performance or users' work.

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CART - Custom Automated Reporting Tool - this tool manages the 60+ reports that are generated each day

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Drive Checker - checks to assure the server's hard drive is not running low on space.

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All Is Well - confirms all reports have run on time

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