Automated Syringe Inspection to Stabilize Capacity
Pharmaceutical company with in-house syringe production
Bottlenecks in manual syringe inspection and cold-chain risks threatened efficiency and product integrity in syringe production.
The challenge
The situation
In syringe production, the manual inspection process could no longer keep pace with production requirements. Backlogs loomed and the risk of product loss rose, compounded by cold-chain risks. A digital transformation of inspection was needed to secure capacity and product integrity.
Our approach
What we delivered
Data-based decision for automated visual inspection (AVI)
Stabilisation of production across three batches, to demonstrate that the automated inspection holds up beyond a single run.
Removal of the bottlenecks in the inspection process that were leading to backlogs and with them to cold-chain risks.
The outcome
Results & impact
No product losses
Stabilized production with no product losses over the period reviewed.
No backlog incidents
Inspection bottlenecks removed without production backlogs.
Sound business case
Positive net present value and rapid payback of the automation.
In summary
Automated visual inspection removes the capacity bottlenecks of manual inspection and stabilizes syringe production across multiple batches.
Related expertise
Automated Visual Inspection →
Describes exactly the replacement of manual visual inspection by an AVI system for parenterals as set out in the case.
Good Distribution Practice. →
Addresses the GDP-compliant safeguarding of the cold chain, named in the case study as a central risk to product integrity.
Digitalization in Life Sciences →
Fits the digital transformation initiative with real-time data analysis and adaptive algorithms that digitalize the inspection process in a GMP-compliant way.
Lean Manufacturing →
Covers the redesign of the inspection workflow to remove manual bottlenecks and stabilize production across multiple batches.
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Sources
- Entourage project experience (anonymised)
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