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How ELPEN Increased OEE by 90% and achieved 299% ROI with Vimachem's Manufacturing Analytics & OEE solution
How ELPEN Increased OEE by 90% and achieved 299% ROI with Vimachem's Manufacturing Analytics & OEE solution
Company Profile
Organization: ELPEN • Company Size: 1450+ employees • Location: Greece, operating in 90+ countries • Industry: Pharmaceutical manufacturing
ELPEN is the leading Greek pharmaceutical company, producing branded generics and value-added medicines across multiple technologies and therapeutic areas. The company invests over 10% of its annual turnover in Research & Development and operates two state-of-the-art production facilities. ELPEN adheres to stringent Good Manufacturing Practice (GMP) regulations, including compliance with Greek EOF and EU GMP standards, ensuring impeccable production conditions that meet global certification requirements.
ELPEN’s commitment to innovation and technological advancement has positioned the company as a key player in the global pharmaceutical landscape. With a focus on high-quality drug manufacturing, ELPEN continuously seeks ways to optimize production efficiency and maintain regulatory excellence.
Elpen's Production Line
Production Overview
ELPEN operates two cutting-edge manufacturing plants, each dedicated to advancing pharmaceutical production. These two facilities, with one located in Pikermi where this case study was conducted on, collectively contribute to ELPEN’s commitment to regulatory excellence and technological leadership, reinforcing its role in high-quality pharmaceutical production.
These facilities specialize in the production of:
- Solid oral dosage forms (including those containing penicillin)
- Liquid oral dosage forms
- Dry powder inhalers (DPI)
- Pressurized metered-dose inhalers (pMDIs)
- Nasal sprays
- Lyophilized
- Liquids for injection
With facilities dedicated to the preparation of a variety of intricate products for international pharmaceutical groups and global export, ELPEN required a technological solution that could support this diverse and complex manufacturing environment while ensuring strict adherence to regulatory compliance.
The Challenge
As market demands evolved, ELPEN sought operational modernization to achieve:
- Greater flexibility in production
- Faster response times
- Cost optimization
- Enhanced productivity
The company aimed to improve equipment uptime, reduce downtime, and gain real-time visibility into manufacturing processes while ensuring compliance with strict industry regulations.
To address these challenges, ELPEN partnered with Vimachem and deployed the Manufacturing Analytics & OEE (MA&OEE) module from Vimachem’s MES Pharma 4.0 platform. This solution was implemented across seven independent and automated packaging lines at ELPEN’s Pikermi site, with one specific line serving as a case study.
"After thorough market research, we opted for Vimachem... Their specialization in developing pharma focused digital solutions fulfilled our specific needs and objectives. We were drawn to the user-friendly interface and streamlined maintenance of the Vimachem solution which made it an ideal fit for our operations."
Eleftheria Pekopoulou
Plant Director
The Solution
Implementation Process
1. Hardware Installation:
- Vimachem Edge IIoT device was installed in a single day, receiving three different electrical signals from existing packaging line sensors.
- Installation required no downtime, as it was completed during a scheduled changeover.
- No modifications to production systems meant re-validation was not required.
- Local technicians were trained to independently expand installation across other packaging lines with minimal remote guidance.
- The simple hardware installation was completed in just one hour while the machinery was in changeover mode.
- Vimachem engineers monitored the software for two additional hours to confirm normal operation once production resumed.
2. Software Configuration:
- Configured remotely by Vimachem without disrupting production.
- A designated ELPEN employee was easily trained to create and modify reports to meet evolving operational needs and ensure ELPEN have an internal expert, so they can independently manage and expand their use of Vimachem.
- Adjustments were made to ensure full compliance with ELPEN’s shop floor norms and procedures.
"Our journey with Vimachem has been truly rewarding. From connecting machines to installing the Vimachem MES platform, we rapidly integrated 6 packaging lines without any production disruptions."
George Vlassopoulos
Head of Engineering
3. Operator Training:
- Line operators received a 1-hour training session on software usage.
- Vimachem trainers provided on-site support during the first production shift to resolve any issues in real-time.
Elpen's Installation
The Results
The collaboration between Vimachem and ELPEN represents a pivotal moment in the evolution of industrial efficiency, powered by technological expertise in ELPEN.
The seamless integration of the ‘Manufacturing Analytics & OEE’ module into ELPEN’s infrastructure has enabled real-time insights into equipment performance, downtime analysis, and production efficiency monitoring leading to a significant improvement in operational efficiency, with OEE increasing from 20% in Week 1 to 38% by Week 21.
Availability rose from 28% to 67% within the same period, directly enhancing production capacity and reducing downtime. The impact was immediate and measurable, delivering an ROI of 299% and enabling the customer to achieve a full return on investment in just 34 weeks.
Key Performance Indicators (KPIs)
Operational Gains
- OEE Improvement: From 20% to 38% over 21 weeks.
- Downtime Reduction: 55% decrease in downtime over five months.
- Stoppage Reduction: Average downtime per disruption decreased from 30 minutes to 10 minutes or eliminated entirely.
- Increased Productivity: Optimized scheduling and improved machine availability contributed to higher production output.
One of the primary benefits of monitoring OEE for ELPEN was the ability to analyze losses and take targeted actions to improve operational efficiency. By consistently tracking the OEE metric, the system demonstrated a gradual, sustainable improvement in equipment performance.
OEE and Availability Evolution
Key Benefits of Vimachem’s Manufacturing Analytics & OEE Module
- Ease of Implementation: Rapid deployment through a SaaS model with modular logic.
- Seamless Integration: Compatible with ERP, RFID, Azure AD, and OPCUA for pharmaceutical compliance.
- Configurable Reporting & Dashboards: Enhanced drill-down capabilities and operator dashboards for continuous improvement.
- Compliance & Support: GxP-validated platform with audit logs and dedicated helpdesk and consulting services.
- Hybrid Deployment: Supports both cloud and on-premises configurations with data from over 135 production lines worldwide.
Conclusion
ELPEN’s adoption of Vimachem’s Manufacturing Analytics & OEE module showcases the transformative power of data-driven manufacturing. By optimizing processes, reducing inefficiencies, and leveraging real-time insights, ELPEN has positioned itself as a leader in operational excellence and pharmaceutical innovation. The collaboration with Vimachem represents more than just an investment in technology-it signifies a visionary leap toward sustainable growth and lean manufacturing.
The strategic integration of this technology has resulted in:
- Reduced downtime and stoppages.
- Increased equipment uptime.
- Enhanced real-time insights into production efficiency.
- A more agile and responsive manufacturing environment.
By optimizing processes, reducing inefficiencies, and leveraging real-time insights, ELPEN has positioned itself as a leader in operational excellence and pharmaceutical innovation. The collaboration with Vimachem represents more than just an investment in technology—it signifies a visionary leap toward sustainable growth and lean manufacturing.
With Vimachem, ELPEN has not only modernized its production operations but has also gained a competitive edge in a fast-evolving pharmaceutical landscape, setting the stage for continued innovation and efficiency in the years to come.
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