CASE STUDY: Penn Pharma, a PCI company

Penn Pharma, a PCI company, takes a gold standard approach to maintenance and calibration

IBM Maximo enables longer-term planning for Penn Pharma, helping to maintain assets more efficiently and minimize disruption to production. It also simplifies compliance reporting and enables trend analysis.

  • Saves time and effort by replacing paper-based processes with intuitive dashboards
  • Simplifies compliance with regulatory requirements and clients' quality standards

01

Executive Summary

Penn Pharma, a PCI company, takes a gold standard approach to maintenance and calibration.

Established over 35 years ago, Penn Pharma, a PCI company, delivers integrated drug development, clinical trial supply and manufacturing services for the healthcare industry. It employs approximately 300 people in the UK, and its global parent company, PCI, employs around 2,800 people worldwide.

It recognized that a maintenance and calibration planning system would help increase availability and service levels at its new contained manufacturing facility. Working with Peacock Engineering, an IBM Premier Business Partner, the company introduced an IBM&reg Maximo&reg Asset Management solution for planned maintenance and calibration scheduling and routing. Maximo enables longer-term planning, helping to maintain assets more efficiently and minimize disruption to production. It also simplifies compliance reporting and enables trend analysis..

Our new facility is completely ‘engineered-out’, which means that the operators and engineers are protected from the environment itself, and importantly do not rely on traditional PPE, making it one of the most advanced facilities globally. By contrast, our maintenance processes were relatively old-fashioned, relying heavily on paperwork; maintenance scheduling was laborious; and it was difficult to spot opportunities for optimization.

Peter Webster

Director of Technical Engineering and Continuous Improvement, Penn Pharma, a PCI company.

02

Introduction

No margin for error.

In the precise world of pharmaceutical manufacturing, a little foresight can make a big difference. For example, if you don’t co-ordinate maintenance and manufacturing schedules, a plant’s overall efficiency can suffer, as vital machines may need to be taken out of production at an inconvenient time.

When Penn Pharma, a PCI company, invested in its new state-of-the-art high containment facility, it wanted to develop a much more proactive, predictive approach to maintenance planning.

03

Challenge

Working with Peacock Engineering, an IBM Premier Business Partner, Penn Pharma introduced an IBM® Maximo® Asset Management solution for planned maintenance and calibration scheduling and routing.

Penn Pharma, a PCI company, realized that an enterprise-class maintenance management system could also help meet the stringent regulations that apply to pharmaceutical manufacturing, and the growing expectations of its safety-conscious clients.

Highly potent compounds make up a growing part of our product portfolio, so it is more vital than ever that production equipment is properly maintained and that both quality and safety are assured. The more transparency and control we have over maintenance, the easier it is to demonstrate compliance both to regulators and our clients.

Peter Webster

Director of Technical Engineering and Continuous Improvement, Penn Pharma, a PCI company.

04

Solution

They implemented a solution that played a key role in demonstrating the new facility’s compliance with the standards expected by both regulators and clients.

Penn Pharma, a PCI company, decided to deploy IBM® Maximo® Asset Management to transform maintenance planning at its new facility, and engaged IBM Premier Business Partner Peacock Engineering to deliver the solution as a hosted service.

Peter Webster expands on the reasons behind choosing this solution: “IBM Maximo software has a reputation as a best-of-breed solution for maintenance management, and we know that other major pharmaceutical companies rely on it with great success. When we looked into finding a partner to help us deploy Maximo, IBM recommended Peacock Engineering as having the best credentials for this kind of project.”

Maximo helps us deliver state-of-the-art capabilities for safe, efficient contract manufacturing.

Peter Webster

Director of Technical Engineering and Continuous Improvement, Penn Pharma, a PCI company.

With IBM Maximo as a scheduling tool for maintenance tasks, Penn Pharma, a PCI company, has gained a centralized point of control. The company’s engineers can now access their own personalized dashboards, which provide instant visibility of the jobs that are due, and the most efficient order in which to complete them.

“The IBM Maximo process is totally paper-free when it comes to maintenance,” says Peter Webster. “Our engineers can use their electronic tablets to see what maintenance tasks are due, and can easily update the system both during activities and when the task is complete. The Maximo system in itself is very intuitive to utilize.”

By eliminating paper-based processes, the move to IBM Maximo contributes to more efficient working practices.

Peter Webster adds: “Our old approach to maintenance scheduling was very labor-intensive. IBM Maximo software is changing that, helping us streamline and accelerate the workflow so that our engineers can focus on performing the task and utilizing their time more effectively.”

05

Results

The company optimized operations by planning maintenance and calibration tasks

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