Pharma Production Line Optimization Reduces Downtime By 49%

Pharma Production Line Optimization Reduces Downtime By 49% For Sanofi

Published On: September 22, 2025

It’s usually the small changes that lead to big results and pharma giant Sanofi proved this with its pharma production line optimization project. The company’s use of SmartSkin technology for this project at their Waterford plant in Ireland resulted in a massive reduction in downtime and an improvement in yield. Here’s what Sanofi did.

Production Line Setup Optimization Project

In the recently conducted Insights Forum 6.0 webinar, Eoin Roche, Reliability Engineer at Sanofi, Waterford explained the company’s approach to proactive maintenance to weed out high pressure points on the line before they damage the product.

The strategic implementation of SmartSkin container twins revealed critical points with extreme pressure spikes that significantly exceeded safe operating levels (40.7 PSI vs. an acceptable 10-15 PSI). Leveraging the live data relayed by the SmartSkin system, Sanofi engineers targeted the issue, quickly restoring optimal operating conditions.

Sanofi using SmartSkin Technologies pharmaceutical solution in different sections of the production line to reduce downtime. — Sanofi employed SmartSkin Technologies solution to optimize their production line, solving issues with vial capping station.

Moreover, recurring pressure challenges previously masked by complex equipment layouts were identified and strategically resolved. The technology allowed the precise localization and immediate rectification of inefficiencies within the vial capping station, significantly improving overall equipment effectiveness (OEE).

Watch the full webinar

Position Your Production Line for Long-Term Success

Eoin shared extensive data points, including a 49% reduction in downtime for the plant thanks to the strategic adoption of SmartSkin technology. The solution package, as you can imagine, allows pharmaceutical companies to focus resources on higher-value activities, optimize production quality, and reduce costs.

To learn more details about Sanofi’s production line optimization project, join our comprehensive webinar featuring real-world examples, strategic insights, and practical advice on implementing SmartSkin technology to upgrade your pharmaceutical production.

Watch the full webinar

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