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Project Profile

Advanced Reliability Centered Maintenance Program for Major Pharmaceutical Company

Project Overview

GenesisSolutions, an ABS Group company, was the worldwide implementation partner for a major Pharmaceutical company's Maintenance Excellence Program designed to implement maintenance best practices, including:

  • Reliability-Centered Maintenance (RCM) program
  • Planning and Scheduling
  • Maintenance, Repair and Operations (MRO) Inventory Optimization
  • Best-practice utilization of SAP PM and Maximo throughout Wyeth’s global pharmaceutical and biotechnology manufacturing network

As part of this effort, GenesisSolutions implemented an advanced RCM program for an injectable vaccine production unit in New York. This was a capacity-constrained lifesaving vaccine for infants with a worldwide annual demand of over 60 million dosages. Monthly production rates increased from 3.2M to over 5.0M in 9 months.

In addition, a lyophilized antibiotic plant located in Puerto Rico achieved a 30% productivity increase. At the same time, production transitioned from three filling lines to two and achieved associated maintenance and spare parts savings. Annual production was increased from 30 million doses to 40 million.

During the same implementation phase, GenesisSolutions implemented the same RCM program for the packaging department of another Puerto Rico plant resulting in a $240M product throughput increase in the first four months of operation.


Our Solution

A vital part of these programs was the Genesis Reliability Analysis for critical equipment. This approach was based on a Failure Modes and Effects Analysis (FMEA), leading to improved reliability from more proactive and less reactive maintenance, a planning and scheduling partnership between maintenance and operations, better spare parts support, and a more substantial calibration program.  

At both the Puerto Rico plants, Genesis developed a maintenance planning and scheduling program that included workflow processes to accomplish annual planning and shutdown planning, including: 

  • Designing a standard operating procedure
  • Developing a planning and scheduling department
  • Training for all plant key stakeholders (operations, maintenance and support personnel) and plant planners/schedulers
  • Defined key performance metrics to track reliability and functional performance

The program was successfully launched using a pilot approach and then deployed plant-wide. 

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