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igital transformation initiatives were crucial in helping a global pharmaceutical giant streamline production processes and overcome operational challenges to accelerate COVID-19 test kit manufacturing.
The COVID-19 pandemic created an unprecedented global demand for diagnostic test kits, putting immense pressure on pharmaceutical companies to scale production. A $608+ billion global pharmaceutical giant that had developed a very accurate COVID-19 diagnostic test faced significant challenges in meeting this demand. The company’s fragmented global operations and disparate manufacturing systems hindered its ability to respond swiftly. So they turned to Marlabs, a leader in digital transformation, to help them overcome these obstacles and streamline their production processes.
The pharmaceutical giant’s existing manufacturing systems resulted from multiple acquisitions, resulting in 40 production lines with various hardware, software, and data schemas. This complex environment made it difficult to track, report, and analyze data efficiently. Consequently, the company struggled to maintain production quality, provide regulators with the required information, and manage its supply chain effectively. They needed a comprehensive digital transformation to address these challenges, and they trusted Marlabs to deliver.
The primary challenge was building an automated and integrated manufacturing information system to streamline the company’s operations. This involved overcoming the following obstacles:
With the world urgently needing more COVID-19 test kits, the company required swift action to address these challenges.
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Marlabs devised a comprehensive solution to optimize the company’s manufacturing and supply chain operations by leveraging advanced technologies such as AI, machine learning, and analytics. The following initiatives were undertaken:
Marlabs implemented AI-enhanced ETL, mapping, and integration tools to extract, organize, and consolidate data from all manufacturing facilities and lines into a single central database. They also developed an automated analysis tool that provided dynamic visualization, rapid drill-downs, and critical analyses, enabling real-time test kit quality and regulatory compliance tracking.
Marlabs introduced an automated, analytics-rich, and scalable planning system to prioritize orders, route raw materials, create inventory plans, and optimize production schedules. In addition, this solution performed extensive scenario planning to assess demand and risks for each item on the Bill of Materials (BOM), allowing for dynamic reallocation of raw materials as needed.
To expedite FDA approvals, Marlabs developed a digitized, end-to-end automated process that reduced report generation and submission time from several hours to under a minute. This allowed accurate, correctly formatted information to be sent to the FDA in near-real time, eliminating manual effort.
Marlabs’ digital transformation efforts resulted in significant improvements to the company’s production processes and supply chain management:
Impressed with Marlabs’ ability to deliver effective solutions, the pharmaceutical giant entrusted them with additional projects, including:
The partnership between the pharmaceutical company and Marlabs highlights digital transformation’s critical role in addressing complex life sciences industry challenges. By leveraging advanced technologies and strategic thinking, Marlabs enabled the company to overcome obstacles, streamline processes, and ultimately deliver more COVID-19 diagnostic kits to those in need. This case study demonstrates the value of Marlabs’ expertise in digital transformation and its commitment to driving innovation and leadership in the industry.
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