Home  /  Recordati Case History

Recordati SpA

Digitization of the Packaging Department | Case Study

Home  /  Recordati Case History

Recordati SpA

Digitization of the Packaging Department | Case Study

Scenario

Recordati is an international pharmaceutical group with headquarters in Milan, Italy and operations worldwide with more than 4,000 employees.
Recordati's top management recognized the importance of integrating digital solutions into a mature operating model in order to ensure greater performance in terms of speed, flexibility, decision-making and competitiveness.

Why did the Recordati group embark on the Lean & Digital Transformation journey?

  • Growing price pressure and shrinking margins.
  • Need to recover efficiency losses related to the introduction of drug traceability (serialization) regulations.
  • Need to increase production capacity and efficiency on some packaging lines.

Areas of intervention

The Recordati Group has chosen Bonfiglioli Consulting and Digibelt, for the digitization of 9 packaging lines.

Goals of the Digitization Project:

  • Automatic acquisition of machine and line status (ON/OFF, running, stopped), parts produced and scrap, without impacting machine certification
  • Automatic logging of activities and times of micro-breaks and maintenance times with declaration of reasons and causes of downtime
  • Data capture from SAP related to production orders (PO)
  • Increased production efficiency resulting in greater effectiveness in terms of analysis and ability to intervene on line stops/causes of slowdowns

In particular, the project focused on:

  • Digitization of packaging lines by implementing sensors to detect useful information:
    • Parts Counting: Laser Sensors
    • Reject counters: Barrier sensors
    • Machine Status: "Smart" rooms
  • Implementation of solutions Lean Industry 4.0 Digibelt:
    • Collect&Analyze for real-time acquisition, of key production data, and digital receipt and sending of production progress data to enterprise legacy systems (no manual entry)
    • Digital Flash Meeting: for real-time visualization and tracking of improvement actions and production problems and real-time processing of production KPIs and graphs

Results

  • Increased productivity by more than 30%
  • Elimination of all manual data processing activities
  • The availability of KPIs at all levels made the efficiency of the department transparent, triggering a culture aimed at continuous improvement

Main objectives achieved

+ 30%

PRODUCTIVITY.

0%

MANUAL DATA PROCESSING IN SAP

+100%

IMPLEMENTING SOLUTIONS FOR THE DIGITIZATION OF PACKAGING LINES