Case Study | Digital Lean for Pharmaceutical Manufacturing Company

Functional Topic

Digital Lean Manufacturing

Project Industry

Pharmaceuticals

Needed Support

1 Lean Manufacturing Consultant

Duration

6 Months

The Challenge

A German pharmaceutical manufacturer engaged Consultport to implement digital lean manufacturing in their production. The pharmaceutical industry faces unique hurdles in applying lean principles. Traditional lean manufacturing originated in discrete manufacturing, while pharmaceuticals rely on continuous processes with strict regulatory demands.

The client’s objectives required tailored strategies for applying digital lean for pharmaceutical environments, addressing complexities such as frequent batch changeovers, regulatory compliance, and batch size variability. They needed a consultant to design and implement digital lean solutions adapted to the full production cycle, from API production to packaging.

Role of Consultport

Consultport quickly responded with a shortlist of three consultants specializing in digital lean transformation, presenting this selection to the client within 48 hours. The chosen consultant had a track record of previous projects in the pharmaceutical industry, with four past projects focused on lean manufacturing optimization.

The consultant’s mandate was clear: integrate real-time data, predictive analytics, and custom lean workflows to ensure flexible, efficient, and compliant production. This approach aimed to minimize downtime, optimize changeovers, and reduce inventory costs by aligning production precisely with demand, essential to meeting the specific requirements of pharmaceutical manufacturing.

The Approach

The consultant applied a comprehensive methodology, focusing on real-time data, customized lean workflows, and predictive maintenance specifically suited to pharmaceutical manufacturing requirements.

Real-Time Data and Monitoring: The project began with installing IoT sensors to capture real-time data across the production line. This digital lean strategy enabled immediate insights into machinery status, batch production cycles, and inventory levels, all integrated into the ERP system for quick decision-making based on demand and regulatory quality metrics.
Customized Lean for API and Drug Production: To address the variability in API and drug production, the consultant developed a lean material flow system. This approach reduced batch sizes without increasing inventory levels, creating a semi-dedicated facility network that improved flexibility in meeting fluctuating demand. Additionally, lean techniques for drug production reduced batch-and-queue production by 10%, stabilizing output.
Optimized Packaging Efficiency: Applying digital lean for pharmaceutical industry extend also to packaging, a critical area due to high-mix, low-volume requirements. By reducing changeover times, this approach facilitated flexible, compliant production processes that met diverse packaging needs with minimal delays.
Predictive Maintenance and Quality Control: Predictive maintenance models formed another key component. These models enabled the client to anticipate equipment issues before they escalated, reducing downtime and supporting adherence to Good Manufacturing Practices (GMP). Predictive quality controls further maintained product consistency, an essential factor in regulated industries.

The Results

After project completion, the client saw concrete results, driven by digital lean principles applied across the production chain:

10% Reduction in Downtime

Real-time monitoring and predictive maintenance minimized unplanned downtime, improving equipment utilization and production flow.

8% Increase in Overall Equipment Efficiency (OEE)

The consultant approach optimized workflows in production and packaging, yielding an increase in equipment efficiency and output stability.

15% Reduction in Inventory Holding Costs

Just-in-time inventory management, a core element of digital lean, reduced unnecessary stock levels, lowering holding costs without risk of shortages.

12% Reduction in Maintenance Costs

Predictive maintenance under the digital lean framework preemptively identified issues, extending equipment life and reducing repair expenses.

The transformation led by the consultant helped streamline our processes and positioned us for stronger market alignment. We’re happy with the results, we look forward to working with them again!

— Director of Manufacturing