Case Study

UST drives pharma efficiency: 12% productivity increase, 15% less waste with real-time monitoring

A pharmaceutical manufacturer overcame quality and productivity challenges with UST’s integrated, real-time production monitoring solution, achieving remarkable outcomes: 12% productivity increase, 15% waste reduction, minimized downtime, and lower production costs. Advanced sensor technology ensured consistent quality standards, setting new benchmarks in efficiency and enabling a proactive, high-quality approach to manufacturing.

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OUR CLIENT

Our client specializes in delivering innovative solutions to optimize manufacturing processes, particularly for pharmaceutical manufacturers. They provide advanced sensor technology and real-time production monitoring systems to enhance operational efficiency, minimize waste, and ensure product quality.

THE CHALLENGE

Environmental control and downtime challenges put quality and productivity at risk

A pharmaceutical manufacturer struggled with significant quality and productivity issues that affected its operations and competitiveness. It lacked a system to monitor ambient conditions within its manufacturing facility, leading to detrimental inconsistencies in temperature, humidity, and other critical environmental factors. As a result, it could not maintain the stringent conditions required for producing high-quality pharmaceutical products. Unplanned production shutdowns caused severe manufacturing line disruptions, leading to process line choking (unexpectedly halting production), significant delays, and reduced productivity. Without a predictive maintenance system, equipment failures were not detected until they had already caused substantial damage.

These inefficiencies caused the manufacturer to struggle to meet production targets and maintain product quality, resulting in increased operational costs and decreased consumer trust. Production delays also made it difficult to scale operations or introduce new products.

Without a centralized production monitoring system, the company was vulnerable to recurring issues in maintaining product quality, ensuring consistent productivity, and reducing operational disruptions.

THE TRANSFORMATION

Optimized manufacturing processes with integrated sensor technology, production monitoring, and real-time data

UST provided a comprehensive solution to optimize manufacturing processes by integrating advanced sensor technology and monitoring systems. UST also implemented ambient temperature and humidity monitors to provide real-time data monitoring on critical environmental factors.

Additionally, UST introduced production line weight sensors to help maintain correct proportions and weights, reduce errors, and ensure regulatory compliance. Movement sensors monitor material flow and machine functions, improving productivity and reducing risk and shutdowns. Cameras with anomaly detection software provide continuous visual surveillance of the production floor, alerting operators in real time and enabling immediate intervention.

Digitalization on the production line and floor created a centralized system to monitor and analyze sensor data in real time. Adopting a more proactive approach to managing operations improved overall operational efficiency, reduced downtime, minimized waste, and ensured consistent high-quality production.

UST’s solution transformed how the manufacturer monitors and controls production, leading to significant quality and productivity improvements. Delivering an integrated, real-time production monitoring solution combining advanced sensor technology and anomaly detection led to consistent production line quality and productivity, setting new standards for operational efficiency and enhanced product quality.

THE IMPACT

Operational excellence in manufacturing automation solutions leads to improved production efficiency

UST’s solutions significantly improved the client’s overall manufacturing process by enabling operators and managers to easily monitor the production process and quickly identify and address issues. Highlights of the UST solution include:

Seamless installation of wireless sensors and cameras monitored in real-time via a single, centralized dashboard, allowing for quick deployment and minimal workflow disruption.
Enhanced monitoring capabilities and real-time data led to 12% productivity improvement, proactive maintenance, quick response times, minimal downtime, 15% waste reduction, optimized use of raw materials, and reduced production costs.
Automated monitoring with cameras and anomaly detection ensured precise and consistent quality without the need for additional manpower.

Learn more about UST’s cutting-edge sensor technology and real-time production monitoring tailored to meet the exacting standards of pharmaceutical manufacturing.

RESOURCES

https://www.ust.com/en/industries/life-sciences

https://www.ust.com/en/sentryvisionai

https://www.ust.com/content/dam/ust/documents/brochure-ust-sentry-vision-ai.pdf