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Optimizing Shutdowns for a Global Pharmaceutical Company: A Case Study in Efficiency and Cost Reduction

In pharmaceutical manufacturing, maximizing production efficiency is crucial. Shutdowns, although necessary for maintenance and safety, often lead to extended downtime, reduced production opportunities, and increased costs. A recent Shutdown Optimization Program for a global pharmaceutical company shows that these challenges can be effectively addressed with the right approach.

 

Customer Goals: The Challenge

This global pharmaceutical giant’s primary goal was clear: reduce the duration of shutdowns to increase production opportunities. They also aimed to optimize preventive maintenance and calibration processes to cut down on operational costs. Avoiding shutdown delays and ensuring a swift return to production was critical, as was supporting the adoption of new global guidelines to enhance good planning and scheduling practices.

 

Solution: A Strategic Approach

To address these challenges, a comprehensive Shutdown Optimization Program was delivered, focusing on a few key areas:

 

  1. Tailored Training: The first step involved specialized training on global Shutdown Planning & Execution guidelines. This ensured all team members aligned with the new standards and understood the importance of efficient shutdown management.
  2. Pre-Workshop Studies: A series of pre-workshop studies was conducted to identify optimization targets. These studies laid the groundwork for actionable timelines and quick wins, setting the stage for a more efficient shutdown process.
  3. Expert Leadership and Technical Support: Subject Matter Experts (SMEs) provided critical leadership and technical support. Their guidance helped the site team develop the necessary skills and knowledge, boosting their competency and confidence.
  4. On-Site Leadership: The program also emphasized strong on-site leadership, crucial in driving the site-based team toward successful reductions in annual shutdown days.

 

Winning Results: Tangible Benefits

The results of the Shutdown Optimization Program were nothing short of impressive. Here’s a breakdown of the key outcomes:

 

  • 36% Reduction in Maintenance Costs: Across three different sites, the program achieved a remarkable 36% reduction in maintenance costs, highlighting the effectiveness of the new strategies.
  • Significant Reduction in Shutdown Duration: The average shutdown duration was reduced by 20 days per target facility—a 35% reduction overall. This minimized downtime and allowed the company to resume production much faster.
  • Increased Revenue Opportunities: The optimization efforts created over $6 million in increased revenue opportunities across three target facilities. This was a direct result of the enhanced efficiency and reduced downtime.
  • Reduction in Engineering OPEX Costs: Engineering Operational Expenditure (OPEX) costs were slashed by $370,000, contributing to the overall financial health of the company.

 

Conclusion: A Blueprint for Success

This case study is a powerful example of how a well-executed Shutdown Optimization Program can drive significant improvements in efficiency, cost savings, and revenue generation. The global pharmaceutical company transformed a traditionally challenging process into a streamlined, cost-effective operation by focusing on training, leadership, and strategic planning. This program offers a proven blueprint for success for other companies facing similar challenges.

Call 866.772.6770 for more information.

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