Automated Syringe Inspection to Stabilize Capacity
Pharmaceutical company with in-house syringe production
Bottlenecks in manual syringe inspection and cold-chain risks threatened efficiency and product integrity in syringe production.
The challenge
The situation
In syringe production, the manual inspection process could no longer keep pace with production requirements. Backlogs loomed and the risk of product loss rose, compounded by cold-chain risks.
Our approach
What we delivered
Data-based decision for automated visual inspection (AVI)
Stabilisation of production across three batches, to demonstrate that the automated inspection holds up beyond a single run.
Removal of the bottlenecks in the inspection process that were leading to backlogs and with them to cold-chain risks.
The outcome
Results & impact
No product losses
Stabilized production with no product losses over the period reviewed.
No backlog incidents
Inspection bottlenecks removed without production backlogs.
Sound business case
Positive net present value and rapid payback of the automation.
In summary
Automated visual inspection removes the capacity bottlenecks of manual inspection and stabilizes syringe production across multiple batches.
Related expertise
Automated Visual Inspection →
System selection, defect library and method validation with a probability-of-detection study
Good Distribution Practice →
Cold chain validation with transport lane studies and GDP-compliant SOPs
Digitalization in Life Sciences →
Risk-based system selection and the validated rollout of digital production systems
Lean Manufacturing →
Material flow and layout design to remove bottlenecks on the line
Similar projects
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Sources
- Entourage project experience (anonymized)
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