Originally Published on: QuantzigHow we Helped Pharmaceutical Manufacturer Reduce Rejection Rate and Rationalize Manufacturing Practice Using Sensor Data
##Elevating Quality and Efficiency in Pharmaceutical Production
Embark on a transformative expedition with a prominent UK-based pharmaceutical giant boasting a market capitalization exceeding $1 billion. Confronted by persistent challenges of surging rejection rates and the imperative to rationalize manufacturing practices, the company turned to Quantzig for groundbreaking solutions, reshaping its operational landscape.
###Client Profile: This pharmaceutical heavyweight grappled with consistent rejection of product batches due to deviations in critical quality attributes, resulting in substantial financial losses and impacting product availability.
###Challenges at a Glance:
High Rejection Rates: Elevated rejection rates led to financial setbacks and availability issues for the client. Root Cause Identification: Pinpointing the root causes of deviations in critical quality attributes posed a significant challenge, affecting manufacturing processes.
###Quantzig's Strategic Solutions: Harnessing the power of advanced analytics and sensor data, Quantzig executed a comprehensive solution to address rejection rates and optimize manufacturing practices.
###Results Achieved:
80% Reduction in Rejection Rate: Targeted interventions led to a substantial decrease in rejection rates. Real-time Visibility to Design Space: Implementation of advanced analytics provided near real-time insights into the design space, enhancing monitoring capabilities. Improved Future Planning: Optimization of manufacturing processes translated into enhanced planning and operational efficiency.
###Industry Dynamics: In the UK pharmaceutical manufacturing sector, optimization is paramount for streamlining processes, ensuring product quality, and fostering innovation. Advanced technologies and data analytics play a pivotal role in minimizing waste, reducing costs, and enhancing overall operational efficiency.
###Navigating Challenges:
Root Cause Identification: Meticulous testing and analysis assisted in identifying root causes of deviations in critical quality attributes. Data Volume Challenge: An effective system for aggregating and analyzing overwhelming sensor data was implemented.
###Quantzig's Strategic Approach:
Infrastructure Establishment: A centralized infrastructure aggregated data from diverse sensors, offering comprehensive visibility into operations. KPI Development: Collaboration with subject matter experts identified crucial key performance indicators (KPIs) for effective monitoring and optimization. Root Cause Analysis: A framework systematically analyzed factors like process parameters and equipment performance to pinpoint precise root causes. Continuous Monitoring Mechanism: Real-time monitoring against predefined SLAs allowed for swift corrective actions.
###Conclusion: Quantzig's tailored solution not only achieved an 80% reduction in rejection rates but also empowered the client with actionable insights for continuous improvement. The proactive approach to manufacturing optimization ensures sustained growth and competitiveness in the pharmaceutical manufacturing industry.
