AstraZenecaImproving Quality by Reducing Variability

Case Study

Solution delivered by Parsec Certified Partner

01 AstraZeneca Improving Quality by Reducing Variability

Utilized TrakSYSTM Features & Functions

Recipe & Batch

Quality & SPC

Electronic Forms

OEE

Weighing & Dispensing

Performance Management

Material Management

Traceability & Genealogy

EBR

Pharmaceutical Industry

AstraZeneca needed a solution that could manage and create a more cost effective supply chain. By improving flexibility and responsiveness AstraZeneca was able to decrease waste and meet market demands.

Regulatory Compliance

02 AstraZeneca Improving Quality by Reducing Variability

Within one year of TrakSYS™

implementation, AstraZeneca

was able to add one million

extra bottles to capacity without

additional capital investment.

03 AstraZeneca Improving Quality by Reducing Variability

AstraZeneca is one of the world’s leading pharmaceutical companies with operations in over 100 countries. The founding of AstraZeneca began in 1999 when Swiss company Astra AB merged with British company Zeneca Group plc1.

Over the next decade AstraZeneca would continue to grow, making numerous corporate acquisitions to enter into new markets and further increase existing market share. AstraZeneca is now a leading global pharmaceutical and biologics company with a portfolio of products for major disease areas including cancer,

cardiovascular, gastrointestinal, infection, neuroscience, respiratory and inflammation. With headquarters based in London, and sites spread across the globe, AstraZeneca had limited real-time performance visibility into its operations.

AstraZeneca’s ‘Lean Operations’ is focused on improving flexibility and responsiveness to customer needs; improving quality by reducing variability and waste; and operating a more cost effective supply chain. For this initiative AstraZeneca turned to Parsec for their solution TrakSYS™.

Company Overview

04 AstraZeneca Improving Quality by Reducing Variability

“TrakSYS™ is used everyday by the majority of our plant’s workforce to better understand productivity. TrakSYS™ is a business critical application for our plant as it would it not be possible to sustain our continuous improvement goals and objectives without it.”

- Paul Nicotra

Senior Management

Controls and Automation

05 AstraZeneca Improving Quality by Reducing Variability

TrakSYSTM Solution Approach

Challenges:

• Apply DMAIC (Define, Measure, Analyze, Improve, Control) principals

• Accuracy and timeliness of manufacturing data into a continuous improvement program

• Engage, empower, and inspire to become more involved in the performance improvement process

• Maintaining the highest product quality while significantly reducing production costs

• Wide variability in needed production time for products

• Schedule compliance

Goals

• Automate OEE data collection and reporting in formulation and packaging areas.

• Identify root causes for equipment downtime.

• Promote operator involvement in the improvement process.

• Improve availability of a water utility system as a pilot to quantify the benefits that could be achieved by having accurate information on system performance, Ozone cycle times, and alarms.

The TrakSYS™ solution delivered by Applied Control Engineering not only had to provide real-time information with trusted accuracy, it also had to deliver the needed functionality to facilitate the AstraZeneca journey.

Figure 1 - AstraZeneca TrakSYS™ ScreenshotEvent Summary Report

06 AstraZeneca Improving Quality by Reducing Variability

TrakSYSTM Solutions Architecture

Business Users

Plant Floor Users(Tablet Coating)

Plant Floor Users (Packaging Area)

TrakSYS™ ProductionServer

Firewall

Dynamic Interfaces

Plant Floor Users(Tablet Compression)

Dynamic Interfaces

ERP

CMMS

TrakSYSTM Solutions Architecture

• In accordance with site IT standards, TrakSYS™ was deployed as a central application server with OPC connection over Ethernet LAN to the SCADA System and SENSORTrak™ data collectors

• SENSORTrak™ high-speed data collectors networked via Ethernet LAN, capture and draw production data from various production systems

• 25 EVENTTrak™ operator interface nodes were placed throughout the facility to enable interaction with the systems (e.g., view information, reports, enter observations, categorize events, etc.)

• 70 concurrent web users across operations and production

• Integration with SAP/MII for KPI visualization on LCDs on the production floor

• Plant-wide user workstations to view production and performance information via standard browser technology

The full site implementation included:

• Formulation areas of tablet compression and coating machines • Packaging lines inclusive of blister, bottle, vial, and hand pack

operations • Utilities - USP Purified Water System

AstraZeneca TrakSYS™ Architecture

07 AstraZeneca Improving Quality by Reducing Variability

With the help of TrakSYS™, OEE

improved 10% - 40% across all

lines, using the simple design of

the TrakSYS™ User Interface.

TrakSYSTM Solutions Results

The following results and related benefits were realized through collaborative engagement and the effective use of the TrakSYS™-based solution:

1,000,000Additional Bottles

per Year to Capacity

VisibilityInto Production

Efficiency in Real-time

SimpleReporting to

Enhance Plant Performance

MotivateOperators to Take

Ownership of Lines

ROIWas Quick and Easily

Attainable

10%OEE Improvement on the Bottle Line

40%OEE Improvement on Multiple Lines

EasilyUnderstood

TrakSYS™ User Interfaces

08 AstraZeneca Improving Quality by Reducing Variability

TrakSYSTM Solutions Results Expanded

• In the first year OEE on one bottle line was improved by 10% adding one million bottles per year to capacity without additional capital investment.

• OEE typically improved 10% to 40% on various lines in areas where TrakSYS™ was deployed.

• Motivated operators by being able to view production efficiency in real-time and make a noticeable contribution toward improvements during the production process.

• Simplified and enhanced plant performance status and reporting in real-time.

TM

Parsec is the developer of TrakSYS™, a proven operations management software application and solution platform designed to significantly improve manufacturing processes. Parsec is committed to providing best-in-class products and solutions to our worldwide community of clients to assist them in optimizing their manufacturing operations. There are thousands of TrakSYS™ licenses in use around the globe in a wide variety of Industries.

TrakSYS™ helps manufacturers to maximize asset utilization and efficiency, increase capacity with no new capital equipment, reduce production costs, decrease lead time, and improve profitability. For more information about Parsec and TrakSYS™, please visit the corporate website at www.parsec-corp.com.

About Parsec

Copyright Parsec Automation Corp. 2016 All trademarks are the property of their respective owners

1. Our History | AstraZeneca Careers. (n.d.). Retrieved January 18, 2016, from http://www.astrazenecacareers.com/about-us/history/

Sources