With one of the most challenging and stringent regulatory environments of any industry, pharma manufacturing requires meticulous adherence to quality standards and process controls.
On top of operating within the boundaries set by this regulatory environment, the pharmaceutical market should also proactively aim to satisfy customer demand. However, maintaining inventories at high levels in an industry where expiration dates are a strong constraint can not be the only answer. Very often we are faced with logistical issues such as complex distribution networks, subject to different local laws, resulting in very high costs. But extreme fragmentation in the networks of manufacturing facilities, sales offices, distribution warehouses, suppliers and the number of actors in the supply chain must not lead to an inability to react.
Flexibility is a primary goal that every company in the industry must seek through improvement and coordination of business processes and also adoption of extremely agile and complex instruments.
The extremely restrictive dynamics in production (traceability, lots, deadlines, contamination) and the rules of sequences optimization require companies to be extremely flexible even in the operational management of production.
A customer from the Pharma industry has successfully completed a project planning finite capacity scheduling.
Because of the various needs of the market and the extreme dynamism of planning, a new project was created afterwards to provide a competitive tool for improving planning in the medium / long term. This new project enabled the automatic generation of a centralized Replenishment & Sourcing (R&S) plan for all production and distribution branches synchronized with a group planner providing guidelines for each plant.
This was the crucial link between the tactical planning of each individual plant and the pre-existing centalized system for production planning, scheduling and monitoring.
The production model has been tested and validated at the management level and is now exported to production branches world wide through incremental roll-outs in different factories, starting with the first two main plants. A specific scheduling tool, pointed to laboratory sequencing activities has been introduced in the field of laboratory management. This tool has been integrated to the Lim system.
The implementation of the technological solution occurred in two different periods, while the roll-out in the branches is still in process. The benefits can be summarized as:
- Increase in the level of service from 90% to 94%
- Reduced medicinal ingredients inventory and specific packaging by 20%
- Reduction of order backlog and partial backlog by 30%
- Improved load balancing and increased media saturation of the lines by 15%
- Reduced lead time of internal transformation by 25%
- Reduction of inefficiencies for program changes, emergencies
- Prioritization of laboratory activities and focus on core activities
Solutions based on the sedApta Suite have been successfully implemented for other customers in Pharma Industry. In particular, there are significant experiences in:
- Istituto De Angeli (Fareva)