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Pharmaceutical Case Study

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Mylan

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Save up to 80% in maintenance costs and achieve 99% uptime in operations

Cost Saving Paperless Solutions to Maintenance Operation Problems


Mylan (formerly Rottapharm Dublin) operates in pharmaceutical manufacturing and is currently one of the biggest names in the sector, exporting to 86 countries from its Irish plant. Following a major acquisition, it was identified that improvements were required in its maintenance operations.

Challenges


Mylan was facing a number of challenges, including doubling the output of their finished products and changing their maintenance operation to reduce costs. Their parent company wanted them to increase efficiency as well as decrease equipment downtime. Many of the Maintenance activities were unplanned, the system largely paper-based, and a typical preventative maintenance job took 16 steps to be completed. It was clear that improvements in costs, effectiveness and downtime were needed.

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Solutions


By applying the PEMAC Maintenance system, including its Web Workflow tool, Mylan would be in position to achieve their core objectives:

Paperless maintenance

The system facilitated the implementation of a paperless maintenance system from work request right through to closing the job – no paper is used in any aspect of maintenance work. This has enabled improved efficiency, remote approval and an environmental benefit.

Intelligent Reporting

PEMAC Intelligent reporting allowed Mylan to achieve best practice in preventative maintenance and enable them to reduce costs, improve operations and maximise uptime

Web Workflow

Using the Web workflow tool, technicians would now be able to view both planned and unplanned work through one interface.

Quick Implementation

Turnaround for full implementation of PEMACs system was less than 6 months allowing Mylan to experience the benefits and cost savings early.

Results


  • The results saw Mylan achieve a fully paperless maintenance environment removing 1 million wet signatures from their workflows
  • They experienced a 64% decrease in maintenance costs, an increase in planned maintenance activities from 80% unplanned to 80% planned within 2 years and a significant reduction in equipment downtime
  • A typical preventative maintenance job was reduced from a 16-step paper process to just 4 steps
  • Mylan also removed 54% of their non-value-added Preventative Maintenance routines once PEMAC was in place, which translated into a 75% saving on Engineering time
  • MTBF also went from 150 minutes to a high of 500 minutes within one year

Overall, these gains were key to bringing Mylan to their win of ‘Factory of the Future’.

“We’re very satisfied with the success of the implementation. It has not only enabled us to achieve our objectives, but it has continued to provide us with significant additional benefits for our operations. PEMAC provided us with a high level of support throughout the process and continues to do so today. We would have no hesitation in recommending PEMAC and their innovative software solutions to any company.”

Wesley Horan – Maintenance Manager, Mylan

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