How you develop MES recipes up to 75% faster

Within the pharmaceutical production the use of a Manufacturing Execution System (MES) becomes increasingly important due to rising demands towards production effectiveness, overall equipment efficiency and saving costs by leveraging digital integration and automation. To avoid falling behind competitors, pharma manufacturers must speed up recipe development and verification in order to support efficient production. It is crucial to analyze and harmonize processes before the introduction of MES or development of a recipe for a new product group. This is where Business Process Management comes into place.

Save up to 30% on costs

At Körber, we understand process harmonization is one of the most overlooked areas where our customers can differentiate for advanced cost-competitiveness and gain strategic advantages in their industry. For that reason, we've created a unique method called "The Process Landscape™" to reach your target processes as easily as possible. If you harmonize your processes before introducing MES and start recipe design within the system, you can produce recipes up to 75% faster than before because you exclude parallel or laborious process steps. 

So, it's much more effective to clean up your processes before you work on a single recipe and look afterwards what exactly will happen and how the operators work off every single step. A clear view of your processes keeps the tailored project on schedule, ensures high quality and reduces costs in particular to OPEX by up to 30%.

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How you harmonize your processes 

Step 1: Recording of the current processes – As is

First of all, the current processes are profoundly recorded by physically following movements of relevant people involved and watching all the steps of machine operation and its documentation. We document the entire procedure with our unique standardized method. It is used as an effective work tool for both the current and target process design. This makes it possible to control meetings in a process-oriented and effective manner, to identify open points for clarification, and to always find the right level of detail. 

Step 2: Definition of the harmonized target processes – To be

Now we define and coordinate the main topics system landscape according to ISA-95 by integration of ERP, logistics and automation layers. This is being followed by the consolidation of the results from the actual processes and preparation of the draft target process (harmonization of language, uniform delimitation of sub-processes and standardization).
At the same time as the target process is defined, an ongoing fit gap analysis is carried out with regard to the functional content of a future MES system or scheduled upgrades. Any gaps that are found are taken into account according to the evaluation. As soon as the current and target process landscapes are available, they form the basis for all further roll-out activities.  
 

It's modular: Start with a partial process

The good thing is: You can test the effectiveness of process harmonization in isolated, small processes like line clearance or format change. Just within 10 to 15 days it's feasible to document the process, evaluate it and give precise recommendations for actions and reveal savings potential by creating customer building blocks which can be verified and reused within other recipes. 

So, if you are about to implement MES or plan a major upgrade, you should evaluate and harmonize your processes first. We at Körber support you in every single step from consultancy services regarding Business Process Management up to the integration of a Manufacturing Execution System making you "Pharma 4.0-proof".

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+ Up to 75% faster production of MES-recipes 
+ Up to 30% OPEX savings
+ Easy-to-use: standardized method according ISA-95 & ISA-88
+ Modular proof of concepts (e.g. for line clearance or format change)
+ Reusable templates for MES prototype recipes 
+ User Requirement Specification (URS) documentation included

+ Free initial consultation (even on-site)
+ >20 years of experience in MES & business processes
+ >97% customer loyalty