Increasing Manufacturing Productivity

Context

A multinational pharmaceutical company with double-digit CAGR had invested in capacity increase worldwide over recent years to respond to rising demand and ensure OTIF. Nevertheless, productivity and OEE on each site remained low, leading to a further decision to balance CAPEX with investments in PC&A (Process Control and Automation).

Approach

In order to increase productivity by reducing workload, human error and variance, a team was formed to implement Batch Mode, firstly focusing on spray dryers and thereafter on the rest of the equipment. Emerson’s DeltaV was selected as DCS. A phased approach was designed and a joint team involving PC&A, QA and Production was formed to implement automation on all major lines.

Results

In the first 12 months, 58 batch recipes were designed and configured, of which 33 become ready / with OQ. Results from batch receipts showed a considerable potential to increase productivity, leading to a decision to significantly expand automation to the remaining equipment and lines.

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