Or how to ensure all your ducks are in a row before firing the first shot.

Overview

Businessman frustrated

If this all sounds like a headache to you, trust us – it was a headache for the Major-Pain-Relief Readiness Team (MRT). But they knew they couldn’t let the pressure get to them. After all, they aimed to make MRT the most successful pharmaceutical-drug launch in history. Everything looked ready to go. Their spreadsheet calculations said they had sufficient capacity to meet customer demand. However, the team lead had a pit in his stomach. Something didn’t feel right. Marketing, advertisements, and conventions were all timed on the release of this product. If the facility couldn’t produce the volumes to meet the projections, there would be hell to pay.

So, they turned to process simulation to take the pain out of production.

Using ProcessModel, the MRT could simulate and analyze every step of the production process, from raw material delivery to final product packaging. Process simulation allowed them to optimize their schedule, identify bottlenecks, and make informed decisions about resources and personnel. And the result? They delivered a flawless pharmaceutical launch that made the lives of people with arthritis a little easier.

So, the next time you feel overwhelmed by the pressure to deliver a top-notch product, remember that you can take the pain out of production with process simulation. Just ask the MRT – they’ve done it before and will do it again (hopefully without any more major pain).

Welcome to the Virtual Factory – where process simulation reigns supreme, and the pain of production is a thing of the past. At least, that’s what The MRT hoped when they turned to ProcessModel to help launch their new prescription medication.

Details

As anyone in the pharmaceutical industry knows, launching a new drug is no small feat. There are countless details and a tight timeline to get everything right. That’s where the MRT came in. This ad-hoc task force managed the introduction and commercial production of Major-Pain-Relief, and they knew they had their work cut out for them.

The MRT decided to use a top-down approach to process simulation, starting with a macro-level model of the entire production process. This approach allowed them to break the project into manageable segments and quickly identify any bottlenecks or issues. The first area they tackled was the warehouse receiving operation, where Esteban Perez developed static inventory models to ensure a smooth flow of materials for the new product.

Lab tech working

But as the MRT integrated the entire Major-Pain-Relief process into a single simulation model, they noticed a problem. A long queue of capsule samples was building up at the entrance to the analytical laboratory, causing delays in the production process.

A sample from every batch requires analysis and certification before the product is released to packaging. If the certification doesn’t return on time, the product backs up, production stops, and production managers become irritable. They severely underestimated original predictions for the staff of the lab.

After a thorough analysis, the MRT discovered that static calculations based on averages didn’t account for the random variability that can occur in any manufacturing process. In addition, ProcessModel showed that the laboratory needed three shifts of chemists working seven days a week to keep up with demand and satisfy cycle time requirements.

Thanks to process simulation, the MRT could identify and solve this issue before it became a significant pain in the production process. And with their virtual factory up and running smoothly, The Company was able to launch Major-Pain-Relief with great success. So the next time you face a daunting production task, remember: with process simulation, you too can take the pain out of production.

And they all lived happily ever after. Okay, okay, that’s a bit of a stretch. But the story of The Company’s Major-Pain-Relief launch does have a fairy tale ending. With the help of process simulation, the team launched the most successful prescription drug in history, breaking numerous records.

But it wasn’t all smooth sailing. The MRT had a challenging task: produce the required launch quantities in three months, package them, and ship them out on time. It was a daunting challenge, but the MRT was up to the task. And while they couldn’t have done it without the help of everyone in the supply chain, they know that ProcessModel was a crucial player in their success.

Thanks to process simulation, the MRT could identify and solve issues before they become major pains in the production process. And the results speak for themselves – The Company’s Plant in Puerto Rico is now the primary supplier of Major-Pain-Relief capsules worldwide, consistently meeting market demands on time.

Now, The Company is making process simulation an integral part of its decision-making process, subjecting new products to simulation modeling to “test drive” the production process and take preventive action early on. In addition, an inexpensive insurance policy helps them take the pain out of production.

So, while this may not be a traditional fairy tale, it’s still a story of triumph over adversity and a happy ending for all involved. And that’s something to celebrate.

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