the case study in a nutshell
This client is an agile and pragmatic pharmaceutical Company whose business is suffering from excess of stock, low equipment saturation and inadequate service level. A situation that in time could seriously jeopardise its leading position within the Italian and European industry. To face this risk, we have initially identified the main gaps in the IT systems and master data management and planned a set of quick actions to improve the overall data quality and information flows. Then we have implemented an AI-based production planning tool that achieves better saturation and better service level than a human performing the same task, in a fraction of the time.
Benefits
The new scheduling tool achieves +5% equipment utilization and +8% service level on an average plan
AI-scheduling allows to reduce by -90% the time spent on manual planning operations
Optimized plans can reduce stock utilization by 5% possibly saving >1M€ each year.
1
Customer profile
A leading API manufacturer based in Italy. Its therapeutic classes are for anticancer treatments, steroids, psychotropics and non-beta lactam antibiotics, as well as for veterinary use.
2
Challenges
- Equipment saturation and service level is unsatisfactory due to very complex production environment and huge number of constraints.
- Planning & scheduling scheduling is still performed manually and is not properly supported by existing tools.
- Master data accuracy and completeness is insufficient.
3
Our solution
- Performed an in-depth analysis of the production planning processes and highlighted the main gaps in the process
- Designed and implemented a completely new AI-based digital tool for production planning to fully replace manual planning
- Planned an action roadmap to improve overall data quality and management