+60K
Employees worldwide
Advanced Manufacturing Delivers 1.4-Year Payback in Pharma
The client produces, for the world market, inhalation products in plants in the UK, France and USA. The sites’ productivity increase targets are greater than 10 percent per year. Industry 4.0 activities are seen as the main lever to achieve this target and, especially as in the production area, several Industry 4.0 elements have already been implemented. To get to the next level the client wanted to have an implementation roadmap for the complete plant network and one partner for the implementation process.
Life Sciences
Manufacturing
Operational Excellence
Operations Strategy and Transformation
Smart Factory
The client is a leading global biopharma company focused on the research, development, and manufacturing of innovative vaccines and specialty medicines. With a strong scientific heritage and a worldwide industrial footprint, the company works to prevent and treat a wide range of diseases, improving health outcomes for millions of people around the globe.
75
Countries
+30
Manufacturing sites
The Challenge
The client needed to accelerate productivity improvements beyond the current Industry 4.0 initiatives already in place.
With ambitious annual productivity increase targets of greater than 10 percent, the organization required a comprehensive implementation roadmap for the complete plant network and a strategic partner to guide the transformation process.
The focus was on identifying and prioritizing the most promising Smart Factory opportunities across material flow and production support functions including quality and maintenance.
Real Results Achieved Together
The comprehensive assessment and strategic roadmap delivered measurable impact across the pharmaceutical group's plant network, establishing a clear path to Smart Factory transformation.
+50
Smart Factory projects identified
1.4
Years payback time for first wave
3
Implementation waves designed
Transformation Impact
Implementation roadmap for these projects in three waves:
- Smart material flow automation
- Predictive maintenance
- Digital shop floor management
Our Approach
The approach we proposed followed three streams:
- Collation of a short list of Industry 4.0 opportunities, starting with 3-day site assessments where the focus was on material flow and other production support functions (quality, maintenance) to determine the as-is situation. We designed an overview of the current process execution, with data flows, IT-systems and an evaluation of the first improvement potentials. In addition to this we jointly identified the most promising Industry 4.0 initiatives that had to be evaluated.
- Identification and evaluation of Smart Factory projects, including the evaluation of investment costs and savings, along with complexity, technical feasibility and implementation effort for a portfolio of 50 Industry 4.0 initiatives, along with a recommendation on which projects should be prioritized and launched
- Implementation plan on the road to the Smart Factory, designing the detailed roadmap to implement Industry 4.0 projects in three waves, defining work packages, required resources and budget for the first wave.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Ready to Transform Your Manufacturing Operations Into a Smart Factory?
- Unlock double-digit productivity gains through strategic Industry 4.0 implementation
- Stop struggling with fragmented digital initiatives that don’t deliver measurable ROI
- Join leading pharmaceutical manufacturers achieving rapid payback on Smart Factory investments
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