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Lean Industry 4.0 Approach in Recordati | Case History

CLIENT PROFILE 

Recordati, established in 1926, is an international pharmaceutical group, listed on the Italian Stock Exchange, with a total staff of more than 4,300, dedicated to the research, development, manufacturing and marketing of pharmaceuticals. Headquartered in Milan, Italy, Recordati has operations throughout the whole of Europe, including Russia, Turkey, North Africa, the United States of America, Canada, Mexico, some South American countries, Japan and Australia.

Recordati is a European specialty pharmaceutical group dedicated to partnering, discovering and developing innovative, value-added products that improve the quality of life and help people to enjoy longer, healthier and more productive lives.

CLIENT SITUATION 

Recordati Top Management has recognized the importance of integrating digital solutions in a mature operating model in order to ensure higher performances in terms of speed, flexibility, decision making process and competitiveness. The Lean & Digital Transformation approach has generated several opportunities: vertical and horizontal integration as well as development of new concepts in products, services, business models.

In particular, shared project goals are:

  • Implementing an automatic data collection system in order to “scale” the calculation of KPIs (i.e. OEE) on all packaging lines.
  • Listing stoppages causes down to single line in order to reduce the so-called “gray area” and to have detailed breakdowns of detected inefficiencies
  • Improving people engagement and their problem solving skills, activating continuous improvement processes capable of attacking losses
  • Reducing time (man-hours) for manual reporting and multiple-source data management
  • Improving the data quality in terms of accuracy, completeness and opportunity to have the data records available without restriction of time and place

In order to reach these goals, the following products have been implemented: COLLECT&ANALYZE, FLASH MEETING and PDCA

OUR SUPPORT 

This project, carried out by Bonfiglioli Consulting and Digibelt, involved the digitalization of the 9 packaging lines in the dept, in order to improve the manufacturing process efficiency thanks to an integrated application of the Lean methodology and the most recent Industry 4.0 technologies.

*Source: Knowledge Office Bonfiglioli Consulting

The project led to:

  • Automatic acquisition of machine and line status (On/OFF, in progress, stopped).
  • Automatic logging of micro-stoppages activities and times alongside the maintenance with declaration of downtimes reasons and root causes.
  • Data acquisition and transfer from / to SAP, related to production order report (OdP).
  • Increase in production efficiency resulting in greater effectiveness in terms of analysis and intervention capabilities on line stoppages / slowdown causes. Main KPIs: OEE level 0 (with DNU) and 1 (net DNU) for the packaging part
  • Losses Deployment
  • Production efficiency
  • Delta speed
  • Format change over
  • Timely availability of more explanatory data on anomalies.
  • Increased time dedicated to value-added activities thanks to the elimination of manual data processing.

*Source: Knowledge Office Bonfiglioli Consulting

VALUE DELIVERED

The implemented SOLUTIONS focuse on:

  • Digitalization of the packing lines in the Milan plant thanks to the implementation of sensors to ensure line certification
  • Two-way integration with legacy information systems to digitalize the distribution of production information

The implementation of Digibelt COLLECT&ANALYZE, FLASH MEETING and PDCA products enabled to achieve the following RESULTS:

  • Substituting paper forms with digital solutions available in mobility and from the desktop
  • Real time acquisition, from sensors to C&A, on main production data
  • Real time processing of KPIs and graphs available on Flash Meeting and remotely
  • On time Tracking of actions towards improvement and manufacturing issues
  • Automatic receiving and sending information about production progress status to company legacy systems without manual input

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