Merck’s West Point, Pa., site utilizes a site-wide business-critical alarm management system built on the Siemens Apogee building automation system with a fully custom front-end operating environment which has passed its end-of- life. It functions 24/7/365 with operators responding to real-time alarms by alerting equipment owners and dispatching response personnel. The system has over 10,000 I/O encompassing traditional and OPC-based points, with physical installations in over 50 campus buildings. Merck is undertaking a multi-year upgrade to migrate this system to Rockwell Allen-Bradley hardware with an Inductive Automation Ignition operating environment. Using this project as a case study, this presentation will discuss key automation design and planning considerations. presenters will explain how to approach large-scale automation modernization projects, highlighting key design considerations and lessons learned to ensure successful project execution. The discussion will cover the requirements definition phase, system architecture, platform vetting and selection, controller and I/O deployment, logistics, commissioning, and startup. Presenters will also examine long-term system owner considerations including flexibility and available support, new installations and expansions, and an evolution outlook with a truly hardware-agnostic front- end in a computerized system landscape with shortening lifespans.

Accelerating speed to market for GMP facilities increasingly depends on decisions made long before construction begins. Early engagement among owners, designers, builders, engineers, and trade partners can significantly influence facility design, execution strategies, and overall project outcomes—particularly in complex expansions and active campus environments. This panel explores how early cross functional collaboration helps teams anticipate constraints, identify risks sooner, and make informed design choices that support efficient GMP delivery. Drawing from recent manufacturing expansions,  renovations on active campuses, and newbuild programs, panelists will share lessons learned on how early involvement of construction, engineering, and key trades influences facility design decisions, constructability, sequencing, and regulatory readiness. The discussion will examine how practices such as early procurement and constructability input, digital coordination, and thoughtful use of prefabrication—where appropriate—can improve quality, enhance safety, and support schedule certainty. Panelists will also address challenges teams encountered when early assumptions did not hold, and how those setbacks were turned into positive outcomes through adaptation and collaboration. Rather than promoting a single delivery model, this session focuses on practical   considerations teams should evaluate early in project planning, including how much influence early engagement can realistically have, where it delivers the most value, and how expectations should be calibrated. Attendees will leave with a clearer understanding of how early engagement strategies can shape GMP facility design and execution to  support speed to market while maintaining compliance and quality.

Moderator – Michael Lanasa

Associate Director of Global Quality Compliance, Merck Research Laboratories

Michael is a dynamic change agent with extensive experience in Quality, Engineering, and Operations within the Biotechnology, Pharmaceutical, and Medical Device industries. He currently serves as the Associate Director of Global Quality Compliance at Merck, where he is responsible for modernizing and streamlining legacy Quality Management Systems (QMS) and implementing digital solutions for Commissioning, Qualification, and Validation (CQV) processes and CMMS.

His expertise spans quality systems, regulatory inspections, strategic planning, plant design including design and start-up, process and equipment validations, technology transfer, and aseptic processing. He has also been instrumental in developing and revitalizing large-scale facilities’ infrastructure, processes, and technology to maximize results in the US and international sites. Michael holds a BS in Mechanical Engineering from Drexel University.

Panelists

General Contractor – Abhishek Dhawan

Executive and Life Science Core Market Leader, DPR Construction

A life sciences executive, Abhishek Dhawan provides strategic, sustainable engineering and construction solutions across life sciences and supporting industries. At DPR Construction, he leads teams of technical builders with a strong planning mindset and deep construction expertise, delivering innovative solutions from early concept through construction. His experience spans brownfield and greenfield projects, lab conversions, facility upgrades, cGMP manufacturing, and warehousing.

Abhishek oversees operations, capital programs, and business planning, helping clients meet growth targets through efficient execution, cost savings, and proactive value strategies. As a director of global integrated delivery, he has led engineering, procurement, and construction teams across the U.S. and internationally, delivering highly regulated pharmaceutical and biotech facilities. With 21 years in the industry, he holds a Master’s in Polymer Science along with Bachelor’s degrees in Chemical Engineering and Chemistry from North Carolina State University.

Design Partner – Anish Thomas

Project Manager, PM Group

Anish Thomas is a seasoned project manager with 19 years of experience leading a diverse portfolio of Capex projects in the biopharmaceutical manufacturing sector. His experience includes large-scale projects that require strategic program-level execution along with small-scale projects requiring an agile and proactive approach. Anish has delivered greenfield, brownfield, and retrofit facility projects, consistently aligning execution strategies with client needs to ensure efficiency, flexibility, and high-impact outcomes.

Trade Partner- Zachary Heilman, PE,

Account Engineer, Southland Industries

Zachary Heilman, PE is a Penn State Architectural Engineering alumni with a focus on mechanical building systems and a depth of knowledge in structural, electrical, and construction for buildings. Zak has 15 years of professional experience with architects, engineers, and construction partners on collaborative delivery projects. For the past decade, he has specialized in mechanical design and construction for technical validated environments and specialty systems: including classified rooms, process piping, ambient/cold storage, and compressed air systems. In his current role, Zak develops custom solutions for pharmaceutical owners through design-assist and design-build delivery. Zak is a firm believer that trade partners add tangible value when engaged early.

Process Equipment – Mark O’Brien

Process Procurement Manager, DPR Construction

Mark brings more than 15 years of experience in the life sciences industry, specializing in the procurement of process, clean utilities, and laboratory equipment for complex biotech, manufacturing, and research facilities. As DPR’s Process Procurement Manager and national life sciences procurement subject matter expert, he leads project teams in developing and executing equipment purchasing strategies that support critical path schedules and regulatory compliance. His work includes contract negotiation, coordination with owners and design teams, review of technical and service requirements, and oversight of the buyout and post award coordination process, all with a focus on risk mitigation and predictable project delivery.

Throughout his career, Mark has successfully managed high value, highly complex supply chains, consistently delivering results on time and within budget. He is known for a metrics driven approach that leverages performance data to reduce risk, control costs, and improve productivity while aligning stakeholder needs. A collaborative leader, Mark emphasizes clear communication and deep understanding of client priorities, recognizing that effective equipment procurement is essential to project success and requires strong partnerships across teams and disciplines. He holds a Bachelor of Science degree in Supply Chain Management and Information Systems from Penn State University.

Presentation #3: 4:00 PM – 4:45 PM

Successful Facility Retrofit: Increase Product Pipeline Capabilities with Limited impact to Existing Licensed Facility/Products