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| ENGINEERING EXCELLENCE |
| DIGITISATION |
| We see digitisation as a means to our goal of affordable medicine and accelerated access. It helps improve productivity, boost quality and enhance safety, while reducing costs. |
| Thus, we are speeding up digitisation across the entire value chain - be it drug discovery, clinical trials, operations or distribution. |
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Our efforts are being driven by three
significant projects: |
Manufacturing
Execution System (MES) |
Optimises business processes in the
production supply chain, improves product
quality and ensures safety of manufacturing
processes, thereby reducing production
costs and increasing compliance. |
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| Laboratory Information
Management System
(LIMS) |
| Effectively manages samples in the laboratory, automates workflows, integrates instruments and manages associated data to improve its efficiency. |
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Learning
Management
System (LMS) |
| Manages training and educational records,
enables research teams to learn collaboratively
over the network and facilitates knowledge sharing about good manufacturing and laboratory processes. |
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| Once implemented fully, these projects will help achieve three large goals: |
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To drive these projects, a digitisation
project structure is in place.
The structure comprises plant teams,
who report to the MES CoE, which
in turn reports to the Central Steering
Committee of Digitisation Project
Management Office. |
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| We are already reaping the benefits of digitisation |
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Eliminated 7,000
batch records |
(about 50 pages each) eliminated
annually due to eBPR |
| 46,400 pages were saved annually |
| due to digitisation of log books |
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Eliminated 1,000
calculation errors |
| annually |
| Eradicated missing entries |
| in batch records |
| Recorded zero instances |
| of misplaced batch records |
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| Instead of 8 hours, now it just takes |
| two hours for batch record review and approval |
| 2 hours spent in data entry per
batch record and associated |
| log books are completely eliminated |
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Speeding Up
Operations with MES |
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| Challenge |
Getting affordable medicines to the market quickly and
successfully is the most significant challenge that the pharma
industry is facing today. The need of the hour was to put in
place a system that reduces the time taken for data collection,
speeds up production, reduces the cost of manufacturing,
monitors operations and reduces errors. |
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| Action |
A manufacturing execution system (MES) was implemented to
enhance operational effectiveness, adherence to quality and
compliance, and to add visibility and transparency to the
production processes. MES is a control system for managing
and monitoring work-in-process on the shop floor. It keeps track
of all manufacturing information in real time, receiving up-to-
the-minute data from machines and employees. |
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| Outcome |
| Activities which were earlier done manually have now been automated through MES and the benefits are mentioned below. |
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Automated calculations |
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Barcode label generation for dispensed material |
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System verification for mistake proof dispensing |
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Integrated scale enables control over weighing |
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Adding into the
process by scanning |
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Transfer to area
by scanning |
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Destination
available in label |
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Sequential execution
of instructions |
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System acts as
checker |
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Availability of
EBR
at station |
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System generated labels (online) |
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Materials are
scanned & stored |
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Easy traceability
of material up to
container level |
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System captures events |
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Possibility of raising events manually |
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Review by Supervisor |
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Automated workflow |
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Real time data recording |
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Electronic review |
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Workflow available |
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Versions of batch record report is possible, if commenting |
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Review by exception concept - system acts as checker |
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System generated batch report in un-editable PDF format |
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| Impact |
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Data collection and monitoring of operations is now automated |
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Data extraction, reliability and security have improved |
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Paper batch records and their related errors have been eliminated |
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Compliance information has been streamlined |
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