GenesisSolutions is the worldwide implementation partner for Wyeth’s Maintenance Excellence Program designed to implement maintenance best-practices including RCM, Planning and Scheduling, MRO Inventory optimization and 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 the injectable vaccine production unit of the Carolina, Puerto Rico plant. Increased month dosage production rates from 3.2M to over 5.0M in 9-months time. In addition, the plant achieved this productivity increase while moving production from three lines to two and achieved associated maintenance and spare parts savings. This is a capacity constrained production unit for a life saving vaccine for infants with a worldwide annual demand of over 60 million dosages.
During the same implementation phase, GenesisSolutions also implemented the same RCM program for the packaging department of the Guayama, Puerto Rico plant resulting in a $240M product throughput increase in the first 4-months of operation. A key part of both programs was the Genesis Reliability Analysis for critical equipment. This approach was based on a Failure Modes and Effects Analysis 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 stronger calibration program.
At both the Carolina and Guayama plants Genesis developed a maintenance planning and scheduling program that includes workflow processes to accomplish annual planning and shutdown planning. An SOP was written, a Planning and Scheduling department created, training conducted for all plant key stakeholders (operations, maintenance and support personnel), in-depth training conducted for plant planner/schedulers and metrics created to track reliability and functional performance. The program was launched using a pilot approach and then deployed plant-wide.
Wyeth Pharmaceuticals (Carolina and Guayama, Puerto Rico)
As part of this effort, GenesisSolutions implemented an advanced RCM program for the injectable vaccine production unit of the Carolina, Puerto Rico plant. Increased month dosage production rates from 3.2M to over 5.0M in 9-months time. In addition, the plant achieved this productivity increase while moving production from three lines to two and achieved associated maintenance and spare parts savings. This is a capacity constrained production unit for a life saving vaccine for infants with a worldwide annual demand of over 60 million dosages.
During the same implementation phase, GenesisSolutions also implemented the same RCM program for the packaging department of the Guayama, Puerto Rico plant resulting in a $240M product throughput increase in the first 4-months of operation. A key part of both programs was the Genesis Reliability Analysis for critical equipment. This approach was based on a Failure Modes and Effects Analysis 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 stronger calibration program.
At both the Carolina and Guayama plants Genesis developed a maintenance planning and scheduling program that includes workflow processes to accomplish annual planning and shutdown planning. An SOP was written, a Planning and Scheduling department created, training conducted for all plant key stakeholders (operations, maintenance and support personnel), in-depth training conducted for plant planner/schedulers and metrics created to track reliability and functional performance. The program was launched using a pilot approach and then deployed plant-wide.