Case studyPharma

Automated Syringe Inspection to Stabilise 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 a three-batch period

Removal of bottlenecks in the inspection process

The outcome

Results & impact

No product losses

Stabilised 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 stabilises syringe production across multiple batches.

Related expertise

Automatisierte Visuelle Inspektion →

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.

Digitalisierung Life Sciences →

Fits the digital transformation initiative with real-time data analysis and adaptive algorithms that digitalise the inspection process in a GMP-compliant way.

Lean Manufacturing →

Covers the redesign of the inspection workflow to remove manual bottlenecks and stabilise production across multiple batches.

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Sources

Entourage project experience (anonymised)

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