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Case Study | Digital Transformation
Recent ActivityRecent Activity
3 minute read

Digital Twins Help Polpharma Maintain Quality

Polpharma now has a user-friendly, smart platform for employee training, maintenance and installation supervision

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Side view of capsule package at production line

For many companies, remote support looks like this: a technician discovers a problem and calls a colleague to walk through the solution. Hours on the phone might lead to a fast solution – or the facility could face a prolonged shutdown.

The Polpharma pharma plant in Starogard Gdański, Poland knew this scenario well. This plant is the only Polpharma facility in Poland that produces large-scale active pharmaceutical ingredients (API), or the active substances for the manufacture of finished drug forms.

Their annual production capacity is 3.9 billion tablets and capsules, and 118 million units in liquid form (injection preparations in polyethylene packaging and glass ampoules, as well as infusion fluids and liquids for external use). Annual API production is 600 tons.

Their broad and varied portfolio and years of experience allow Polpharma to offer modern products and solutions to pharmaceutical companies worldwide. About 20% of the substances they manufacture are used for the production of their own finished drug forms. The rest are intended for external companies, 95% of which is exported, mainly to other EU countries and to North America, Latin America, North Africa, Korea and Japan. They are present on six continents, and their market position is growing.

So when something goes wrong, the shutdown can affect millions of people.

Smart Industry DX Trailblazer logo

"Before Polpharma’s digital transformation, remote support consisted of phone calls between technicians."


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Digital Twins Help Polpharma Maintain Quality
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Solving Problems the Old Fashioned Way

The technical staff in the field often relied on smartphones to solve problems – they called each other.

Before the augmented reality (AR) Industrial Internet of Things (IIoT) pilot project, users monitored the installation and condition of equipment through a SCADA system at operator stations.

Now, Polpharma has a digital platform based on PTC®’s Vuforia® Chalk AR and ThingWorx® application, part of FactoryTalk® InnovationSuite

.

Polpharma creates digital twins

to monitor the parameters of assets. By digitally bringing their mechanical designs to life, they can “see” problems and rely on remote subject matter experts and technical staff to solve problems efficiently and precisely.

World Leader Improves Maintenance and Support

The remote aspect of this solution is increasingly important, especially with pandemic constraints. The result is a user-friendly, smart platform for training new employees, effective maintenance, and supervision.

In addition to improved maintenance and support using smart AR applications connected to the ThingWorx® platform, the team appreciates new functionalities, including online calculated KPIs, prediction of failure for assets, online access to technical documentation, Top 10 alarms and an interactive operator help system for maintenance work.


"Polpharma has a user-friendly, smart platform for training of new employees, effective maintenance and installation supervision."


Double Digit Improvements

Polpharma worked with Rockwell Automation to create a global digital transformation

 process supported by top management.

“What surprised me was time-to-market for this project,” said Buca. “Many milestones were actually on time, despite a very short implementation time.”

Based on early results, the team was able to reduce failure removal time 10-15%, reduce energy consumption by technical assets by 15-20%, and achieve a 10% decrease in maintenance time by more efficiently solving technical problems via remote support for technical staff on site. This option, according to Polpharma, was crucial during the pandemic.

After the pilot project, the solution was implemented in two additional locations.

Published June 30, 2022

Topics: Pharmaceutical Life Sciences Industry Metadata Accelerate Digital Transformation Digital Transformation
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