Case Study
How AstraZeneca Improved Line OEE Up to 40% with TrakSYS
AstraZeneca now produces 1,000,000 additional bottles per year since implementing TrakSYS.
TrakSYS improved multiple line OEE by 40%, with bottle line OEE up 10%.
25 operator-oriented screens gave AstraZeneca real-time production and performance visibility across tablet compression, coating, and packaging lines.
TrakSYS is used every day by the majority of our plant's workforce to better understand productivity. TrakSYS is a business-critical application for our plant, as it would not be possible for us to sustain our continuous improvement goals and objectives without it.
The Company
AstraZeneca is one of the world's leading pharmaceutical companies, with operations in over 100 countries. Headquartered in London, AstraZeneca is a global pharmaceutical and biologics company with a portfolio of products spanning cancer, cardiovascular, gastrointestinal, infection, neuroscience, respiratory, and inflammation.
AstraZeneca's Lean initiatives focus on improving flexibility and responsiveness to customer needs by improving quality, reducing variability and waste, and building a more cost-effective supply chain. To get the visibility it needed and maximize the impact of that Lean initiative, AstraZeneca began working with Parsec Automation, LLC certified partner Applied Control Engineering to design and implement a TrakSYS rollout.
The Challenge
With sites spread across the globe, AstraZeneca had limited real-time performance visibility into its operations. Disparate implementations left no unifying system for operators to view data and communicate, and with no way to monitor, compare, and contrast performance data between facilities worldwide, the causes of downtime and quality loss were often unidentifiable.
The Solution
Applied Control Engineering worked closely with various departments to build a comprehensive TrakSYS rollout, integrating TrakSYS with AstraZeneca's existing SCADA and ERP systems. Twenty-five operator-oriented screens were placed strategically throughout the factory to promote user fluency and engagement, and plant-wide user workstations let teams view production and performance information related to tablet compression, coating machines, and packaging lines, including blister, bottle, vial, and hand pack operations, along with utilities.
The Impact
AstraZeneca now produces 1,000,000 additional bottles per year, with multiple line OEE up 40% and bottle line OEE improved by 10%. Operators and managers have real-time performance data where they once had none, plant-wide reporting is optimized, and operator engagement in the improvement process is stronger across the board.
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