Paperless manufacturing and data analytics for Pharma industry
Case in Point: Digitalizing Wire and Cable Industry OEMs for Industry4.0
At a glance
Focus: Paperless manufacturing and data analytics for Pharma industry.
Challenge: The customer is one the largest manufacturer of generic medicines in India
Approach: MES eBR (electronic batch records) based solution from Siemens is responsible for maintaining customer’s Master Batch Record which documents the performance data and deviations along with manufacturing data
Impact: The ingenuity and innovative spirit of the team lies in understanding customer needs, study end to end plant operations and arrive at a win-win digital situation
Siemens India
Siemens India manufactures steam turbines, turbo compressors, high-voltage switchgear (circuit breakers, disconnectors and gas-insulated switchgear), switchboards, remote monitoring systems (RMS), fire detectors and suppression systems, motors and generators, relays and Smart Grid systems, transformers, and advanced medical imaging equipment. The factories replicate global, best-in-class manufacturing systems and practices, with a facility to overhaul and repair gas turbines, compressor blades and rotors.
Siemens India is a leader in technology solutions for intelligent (smart), sustainable cities, smart grid, building technologies, mobility and power distribution. Siemens is involved in the Restructured Accelerated Power Development and Reforms Programme (R-APDRP) of the Government of India for installing Smart Grid solutions in many cities in India. Siemens India has signed a Memorandum of Understanding with Confederation of Indian Industry (CII) to be the Lead Industry Partner in a consortium for the conceptualization and development of Smart Cities in India.
For over six decades, Siemens India has been the preferred technology solutions provider, conceptualizing and implementing various flagship projects in Mobility, Energy Management, Power and Gas, Smart Cities, Intelligent Infrastructure, Industrial Applications, Healthcare and Smart Financing. Siemens India is also strengthening its digitalization portfolio and working on select applications in the country.
Siemens India develops skills with Corporate Citizenship initiatives like ITI upgradation, faculty development, Technical Skills Development Centre and Scholarship Programs for meritorious Engineering students. The company has signed Memorandums of Understanding with the Government of Gujarat and Steel Authority of India, and works with industry bodies, such as Automation Industry Association, Indian Machine Tool Manufacturers Association and CII, to impart technical education. Siemens also has initiatives for sustainable and integrated community development in rural areas.
Digitalizing Wire and Cable Industry OEMs for Industry4.0
Indian MNC headquartered in Mumbai, India that manufacturers and sells pharmaceutical formulations and Active Pharmaceutical Ingredient (API) to over 150 countries worldwide with over 40 state-of-the-art manufacturing sites spanning 6 continents
Business challenge
The customer is one the largest manufacturer of generic medicines in India. In line with the industry regulatory norms, the company is also subject to frequent audits from FDA, who verify how drugs have been produced, and that there is complete traceability and accountability throughout the manufacturing process
Increasing global competition is leading to erosion of margins in this industry. This coupled with rising costs requires the customer to optimize productivity and maintain consistent quality to stay competitive.
Industry 4.0 solution
MES eBR (electronic batch records) based solution from Siemens is responsible for maintaining customer’s Master Batch Record which documents the performance data and deviations along with manufacturing data, for all batches produced in a plant.
Collation of such manufacturing data across batches, across plants, in digital format enables application of analytical tools to derive valuable insights which can in turn enable – Prediction, Benchmarking & Optimization of resources & production.
Presently all batch data resides in the database of MES eBR. The process data resides in the control system. Once we have historical data from all the plants of the customer, we plan to use cloud-based Business Intelligence tools for data analysis to derive valuable plant insights for the customer.
Key benefits
| Area | Outcome |
|---|---|
| Quality | The ingenuity and innovative spirit of the team lies in understanding customer needs, study end to end plant operations and arrive at a win-win digital roadmap. With this project we have helped the customer to make their production completely paper-less resulting in improved flexibility, productivity and consistent quality. |
| Quality | Improvement in plant performance and output quality via valuable plant insights through analysis of batch data. |
| Traceability & Compliance | Simplification of audit process. Truthfulness and integrity of data is established. |
| Energy & Sustainability | Reduction in carbon footprint by moving from paper-based to paper-less. |
Technologies used
Change management and implementation
We are creating value by addressing the challenges of Indian manufacturers with an integrated Digital Enterprise approach. We formed a cross functional team cutting across verticals and ensure that all our projects are agile and customer centric. The Siemens’ team stepped in to implement the customer’s vision of digitalization and drive the transformation for Indian manufacturers by kickstarting their i4.0 journey.
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