Supply Chain Visibility, Drug Wastage Reduction Leveraging Industry 4.0 for Global Bio-Pharma Membrane Manufacturer

Client

Our client is a leading global provider of integrated services, superior delivery technologies and manufacturing solutions for drugs, biologics, cell and gene therapies, and consumer health products. 

Challenges

• Manual order tracking and reporting processes were time consuming.
• Discrepancies in incident reporting and no real-time alerts to put material back to cold storage environment leading to losses. 
• Material handling data visibility was low leading to low accuracy while tracing material.

LTM Solution

• Cloud-based IoT solution for monitoring and reporting of cumulative excursion time with alerts/ notification for breaches in case of aberrations. 
• RFID tags-based tracking of material containers with readers at cold storage facility entry and exit points to monitor In-Out operations. 
• Highly accurate material handing data for operations, reporting to customers, and statutory requirements.
• Monitoring of specific parameters like temperature, humidity for containers, and detection in case of threshold breach. 
• Integration of material visibility data with Handheld Terminal (HHT) devices for realtime alerts to shift supervisor for corrective actions and remote troubleshooting. 

The solution features resulted in:

• Better visibility on material. 
• Better Asset utilization. 
• Reduction in drug wastage. 
• Automation and Higher accuracy of Time out of Environment (TOE) Calculations. 
• Maintain history of excursions for analysis. 
• Alarms to take corrective action to reduce incidences of TOE exceeding limit.

End to End Asset visibility and authentication

• Automated traceability of containers, across all stages of supply chain – right from production to processing and shipment.
• Just-in-time shipments and transportation based on actual forecasts. 
• Automated allocation of container to trailer/supplier, based on the accurate stage of shipment and the actual requirement.
• Ad-hoc and configurable reporting features for advanced data analysis and report views

Business Benefits

• Increased accuracy of TOE calculations by 60% with container traceability.
• 25% reduction in losses by avoiding drug wastage with real-time material visibility.
• Automated real-time alerts to supervisor for corrective actions. 
• Automated monitoring of temperature excursion.