Reliability in pharmaceutical manufacturing is critical for minimizing downtime and ensuring consistent, high-quality production. A recent initiative at a global pharmaceutical company’s flagship manufacturing plant in Asia highlights how targeted training and process improvements can significantly enhance the competence of reliability teams, leading to measurable improvements in plant operations.
Customer Goals: Addressing Core Challenges
The company identified several key areas where improvements were necessary:
- Upskilling the Reliability Team: The primary goal was to improve the competence of the reliability team, including site leadership, managers, engineers, and new hires. The aim was to develop a robust reliability function that could be extended across multiple site teams.
- Reducing Unplanned Downtime: Increased competence was a critical factor in reducing unplanned downtime, directly impacting production efficiency and costs.
- Enhancing Equipment Reliability: Improving equipment reliability through better practices and understanding was also a significant focus, aiming to deliver a more stable and efficient production environment.
Solution: Tailored Training and Competence Building
The following strategies were implemented to address these goals:
- Reliability Training Programs: Tailored modules covering nine key reliability areas were developed and delivered to various teams. This foundational training was designed to move the team from a basic understanding to an advanced level of knowledge.
- Competence Framework Development: A bespoke reliability and maintenance competence framework was created to guide the teams’ daily operations and ensure consistent application of best practices.
- Competency Assessments: During training, competency assessments were carried out to monitor progress and identify areas for further improvement.
- Interactive Workshops: Specific training materials and workshops were developed to engage the teams actively and enhance their learning experience. These sessions focused on critical areas such as Root Cause Analysis (RCA), Failure Modes and Effects Analysis (FMEA), and Bad Actor analysis.
Winning Results: Measurable Improvements
The program led to several significant outcomes:
- Enhanced Competency: The reliability team’s competency was improved from basic to advanced, resulting in a deeper understanding of reliability practices.
- Reduced Risk of Downtime: With the new skills and knowledge, the risk of unplanned downtime was notably reduced, leading to more consistent production schedules.
- Improved FMEA Application: The team’s ability to apply FMEA improved, leading to better identification and mitigation of potential failures.
- Thorough RCA Implementation: The teams conducted more thorough RCA processes, effectively addressing the root causes of problems rather than just treating symptoms.
- Mature Hire Requirements Eliminated: The combined increase in competence across existing teams eliminated the need for mature hires, optimizing internal resources.
- Recognition for Teamwork: The project was recognized as “The Best Teamwork in a Project” at the company’s Global Engineering awards, underscoring the success and impact of the initiative.
Conclusion: Building a Stronger Reliability Function
This case study underscores the importance of targeted training and competency development in improving reliability within pharmaceutical manufacturing. By focusing on upskilling teams and embedding best practices, the company reduced downtime and enhanced overall equipment reliability, setting a new standard for operational excellence.