CHALLENGE: MANUAL PROCESSES LEADING TO HIGH COSTS AND A LACK OF PREDICTIVE CAPABILITIES
The company’s goal in the manufacturing space is to achieve maximum product throughput with zero defects. To support this strategy Pacira started a Continuous Improvement journey in 2016 leveraging Lean and Six Sigma methodologies. Lean helps to ensure the required stability of manufacturing processes, eliminating waste and allowing steps to flow smoothly with no interruptions, delays or bottlenecks for improved time to market. It also allows customers to “pull” the product as needed. Six Sigma helps to reduce variability using appropriate statistical tools for in-process control. Additionally, Design for Six Sigma can improve process robustness. All these approaches rely on leveraging data generated across the organization.
Data gathering was previously very cumbersome for Pacira, as data resided in paper-based documents, spreadsheets and complex equipment systems. For data to be useful, it is necessary to know what data is available, when it was created, its format, and whether it is qualitative or quantitative data. Gathering and formatting data was taking too long and they were unable to garner insights from the data for impactful decision making. Manually aggregated data sets represented only 15% of the total parameters their teams measured and the model could only explain 59% of the results. These gaps were what drove Pacira to look for a solution that could accelerate data aggregation, modeling and prediction.
Pacira identified BIOVIA Discoverant as the solution for Tech Transfer and early commercialization, which best supports their goal to improve yield and time-to-market while optimizing product quality.