Improvement of lab productivity and operational efficiency using IoT / M2M

Significance of the Topic

The global shift to minimize on-site staff during health crises and increase efficiency has accelerated the need for remote laboratory operations. Integrating IoT and M2M technologies ensures continuous analytical workflows, improves resource utilization, and supports secure telecommuting in quality control, research, and production environments across pharmaceutical, food, and chemical industries.

Objective and Overview of the Study

This work by Shimadzu Corporation explores the adoption of digital transformation strategies—such as automated error detection, remote instrument control, predictive maintenance, and virtualization—to boost laboratory productivity and operational efficiency while mitigating the impact of reduced on-site staffing.

Methodology

• Implement machine-to-machine telemetry to transmit instrument status, consumable levels, and error logs to cloud servers without manual intervention.
• Enable remote access and control of instruments via LabSolutions Direct using web browser and VPN connections.
• Deploy AI-based auto error detection and recovery to address flow interruptions caused by air bubbles and other anomalies.
• Monitor mobile phase volumes with gravimetric sensors to prevent shortages and safeguard column integrity.
• Use Shimadzu Smart Service Net to predict consumable replacement and schedule maintenance based on historical usage.
• Adopt virtualization and secure data compression for remote desktop operations, allowing full control and data analysis from any location.

Used Instrumentation

• Shimadzu UHPLC and HPLC systems with Smart Flow Control (FlowPilot) for gradient ramping.
• MPMChecker bottle holders equipped with gravimetric sensors for mobile phase monitoring.
• LabSolutions Direct software for VPN-enabled remote instrument control and data analysis.
• Shimadzu Smart Service Net platform with M2M routers for cloud-based monitoring and maintenance scheduling.
• Virtual desktop infrastructure (e.g., XenApp) for secure telecommuting and remote application access.

Key Results and Discussion

• Gradual pressure ramping increased column lifespan and prevented sudden damage during UHPLC start-up.
• Auto error detection reduced downtime by automatically recovering from flow rate drops and air bubble events.
• Real-time alerts for consumable shortages prevented workflow interruptions and optimized inventory levels.
• Remote access allowed uninterrupted sample preparation, data acquisition, and analysis, enabling efficient telecommuting.
• Predictive maintenance scheduling lowered emergency service visits and improved overall instrument uptime.

Benefits and Practical Applications of the Method

• Enhanced throughput through automated start-up and error handling routines.
• Reduced on-site staffing needs while maintaining high analytical performance.
• Cost savings from proactive consumable management and minimized downtime.
• Scalable solution for diverse analytical environments, including pharmaceutical R&D, quality assurance, and industrial monitoring.

Future Trends and Potential Applications

Integration of advanced AI algorithms for predictive diagnostics and automated troubleshooting.
Development of digital twin models to simulate instrument behavior and optimize maintenance schedules.
Expansion of interoperable IoT standards for cross-vendor instrument integration.
Adoption of edge computing to enhance data processing speed and security on-site.
Integration with robotic sample handling systems for fully automated laboratory workflows.

Conclusion

The implementation of IoT and M2M technologies as demonstrated by Shimadzu supports a resilient 'New Normal' laboratory environment by enabling remote instrument control, automated error recovery, and predictive maintenance, thereby improving productivity, reducing costs, and ensuring continued analytical performance under constrained on-site conditions.

References

Yanagisawa T, Ono K, Yoshida T, Maeda Y, Watanabe K, Inoue T. Improvement of lab productivity and operational efficiency using IoT/M2M. Pittcon Conference & Expo Virtual Event; March 8-12, 2021.