Enabling a €1.1 Million Efficiency Gain in Year 1 Through Mobile Asset Tracking

Asset Tracking

Production Optimisation

Location: Ireland
Facility Type: Oral Solid Dose Pharmaceutical Manufacturing
Assets Tracked: Mobile Production Vessels & IBCs
Return on Investment (ROI): Production Increase of 37 Batches / Year (€1.1 Million Efficiency Gain)
Project Date: September 2023

PlantQuest embarked on a project at one of Europe's largest oral solid dose pharmaceutical sites in Ireland, a sprawling brownfield site initially built in 1992. This endeavor showcased the transformative potential of mobile asset tracking and PlantQuest's asset mapping solutions. The implementation yielded a remarkable Return on Investment within months, resulting in an impressive annual efficiency gain of €1,070,000.

The Challenge Faced

To improve operational efficiency and address persistent challenges with Intermediate Bulk Containers (IBCs), our client required a solution that could:

Introduce an advanced system to track and optimize mobile production vessels.
Streamline IBC handling and movement across two separate buildings.
Scale IBC inventory from 25 units to accommodate a 50% market-driven increase.
Eliminate inefficiencies and delays associated with IBC turnaround and clean campaign management.
Enhance IBC tracking across facilities for greater location clarity.
Reduce bottlenecks and downtime through improved visibility into IBC movement and availability.

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The Solution

PlantQuest implemented a cutting-edge tracking and monitoring system designed not only to locate IBCs in real time but also to provide comprehensive insights into their status and usage. The system included:

Alerts for clean campaign durations and hold times, enabling proactive management of clean and dirty assets.
Advanced tracking capabilities to pinpoint the exact location of each IBC, ensuring seamless coordination across buildings.
Tools to monitor the condition and readiness of IBCs, reducing delays caused by unclear asset status.
Comprehensive data analytics to support strategic decision-making and continuous process improvement.

This solution established a streamlined operational framework where assets could be easily located and managed, minimizing downtime and maximizing production capacity.

The Outcome

The results of PlantQuest’s solution were transformative for the client’s operations. Key achievements included:

50% Reduction in Waiting Times: Mobile vessel waiting times were halved, leading to annual savings of €45,000.
Improved Clean Campaign Compliance: Instances of IBCs exceeding clean campaign or hold times decreased by 50%, preventing up to four investigations per year and saving €100,000 annually.
Enhanced Production Capacity: By reducing lost time, the facility gained the ability to produce an additional 37 batches annually, generating €925,000 in additional revenue.

Enabling a €1.1 Million Efficiency Gain in Year 1 Through Mobile Asset Tracking

The Challenge Faced

The Solution

The Outcome

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