Optimizing Operations While Reducing Capital Costs

Vantage Consulting Group cut costs by $8 million on a serialization project for a pharmaceutical contract manufacturing and packaging organization (CMO/CPO). The CMO/CPO has 14 lines across three sites. Vantage lead the corporate steering committee and managed the project from inception to completion. That included engineering, startup and validation. Vantage provided the methodology and resources to keep the project on schedule and under budget. The project, originally budgeted for $20 million, is now underway for $12 million.

Multiple Sites & Lines, One Goal

A manufacturer with 10 production lines at two sites brought Vantage Consulting Group in to manage a $10 million analysis and scoping project for its Level 4 line and warehouse. Vantage’s project management consultants and manufacturing automation team had overall project responsibility, including engineering, startup and validation. We provided the methodology and resources to bring the project in on schedule and at budget.

Reduced Downtime, Improved Results

Vantage has taken over a serialization project for a major pharmaceutical company that realized after completing 40 of its 100 lines that the changes they were implementing were not consistent and stood to raise costs. Vantage now handles pre-quote engineering and solution definition, including management of vendor quoting through its Streamlined Serialization™ process. Our project management consultants ensure consistent design and planning across all sites and lines and delivers reduced downtime on each line by an average of two weeks.

Engineering, Startup & Validation

A controlled substance manufacturer brought in Vantage Consulting Group to manage a $15 million serialization project on seven production lines at one of its sites. Vantage is responsible for engineering, startup and validation. Vantage’s methodology and resources have kept the project on schedule and at budget. The manufacturer also retained Vantage to plan and budget the second phase of the project.

Developed and implemented automation strategy for world’s largest commercial bakery

One of the world’s largest food processing companies chose Vantage to design and execute the manufacturing automation strategy for over a dozen lines in its new commercial bakery in Mexico.

Vantage’s experienced process engineering and automation team developed the automation strategy and directed the design of all system processes. The project culminated in the bakery’s successful launch.

Vision System Reduces Waste

A Vantage client needed to reduce material waste and identification errors on finished product pallets. Their big-box store customers would not accept shipment if pallets were incorrectly wrapped. Vantage designed and installed a vision-based identification system that automated identification of finished pallets on the move and integrated it with existing control systems.

Our solution sorted and performed correct wrapping operations on each pallet. It automatically and correctly identified pallets 100 percent of the time, reducing the need for expensive extra labor and rework. The system was tested without interrupting production

Developed, Implemented & Tracked a Successful Validation Strategy

Vantage was engaged by a major pharmaceutical company that was implementing a serialization project on two packaging lines. The customer lacked the resources to develop and execute the validation strategy. Our team was not only experienced in developing validation master plans and IQ/OQ/PQ protocols, we also had subject expertise in qualifying a serialization solution. Our project management consultants ensured that all the documentation was developed, including a traceability matrix, worked closely with the solution providers, executed all the protocols and authored the final summary reports – all ahead of the original schedule.