Maximizing OEE in pharmaceutical fill-and-finish: A data-driven approach to reducing downtime and improving quality
In pharmaceutical fill-and-finish operations, maintaining high Overall Equipment Effectiveness (OEE) is essential not just for efficiency, but for ensuring product quality, regulatory compliance, and cost control. In this blog, we will explore how a data-driven approach to OEE investigation combines real-time data with scientific analysis to guide impactful line modifications and reduce downtime.
Why fill-and-finish lines struggle with OEE and how to fix it
In the recent Insights Forum 6.0 webinar, Marius Römer, Product Manager Services at SCHOTT Pharma AG & Co. KGaA, identifies two major pain points in today’s filling lines: underperformance and quality-related issues. These are primarily driven by:
- Unplanned downtime: Interruptions due to maintenance or quality concerns reduce equipment availability and OEE.
- Frequent changeovers: Small batch sizes often necessitate frequent line adjustments, which can lower performance.
- Quality losses: Defects such as glass imperfections or contamination (e.g., particulates) can lead to batch rejections, negatively impacting the quality component of OEE.
The result? Lines frequently operate below their intended speed, and container defects or breakages contribute to rejected batches - both of which are interconnected and lead to overall efficiency loss.
Enhancing Fill-Finish Operations with SmartSkin.
Learn how one fill-finish facility identified defects early, reduced downtime, and improved line performance.
SCHOTT Pharma’s SmartSkin-powered Line Investigation strategy
To address these challenges, SCHOTT Pharma has developed a structured Line Investigation methodology that integrates SmartSkin technology with rigorous lab-based testing:
- Visualizing the unseen: SmartSkin’s Digital Container Twins map pressure, shock, and stress points across the line in real time, revealing where containers are exposed to damaging forces.
- Quantifying the impact: Containers are sampled before and after key line segments and tested in SCHOTT Pharma’s ISO 17025-accredited lab to assess mechanical strength and identify the root causes of breakage.
- Guiding line modifications: Insights from SmartSkin and lab testing inform precise line modifications that reduce stress, enhance container handling, and boost OEE.
- Verification: Post-modification testing confirms improvements in glass durability and a lower likelihood of failure.
“Only laboratory-based mechanical strength testing can confirm whether a detected stress point actually weakens the glass, turning data into actionable evidence.” - Marius Römer
Watch the Insights Forum 6.0 on-demand webinar to see how SCHOTT Pharma uses SmartSkin’s advanced technology to uncover hidden stress points in fill-and-finish lines. The SmartSkin container twins provide real-time visibility into pressure and shock zones, helping teams identify where glass containers are most vulnerable. These insights are visualized through SmartSkin’s proprietary software, transforming raw data into actionable strategies for improving line performance and product quality.
