Pharma Manufacturing Challenges
FDA inspections, equipment qualification, and complete documentation traceability are non-negotiable in pharmaceutical manufacturing.
Case Study: Large Molecule Biologics Manufacturer
How a leading biologics producer achieved FDA compliance excellence while reducing maintenance costs by $2.1M annually.
Phase 1: Compliance Gap Analysis (Month 1-2)
Pre-approval inspection was 6 months away. Equipment documentation gaps presented significant regulatory risk.
820 pieces of GMP equipment with incomplete maintenance histories
Qualification records stored in 14 different locations (paper and digital)
No systematic method to prove equipment fitness for intended use
Manual calibration tracking resulted in 23 overdue calibrations
Phase 2: System Implementation (Month 3-4)
Rapid deployment of Reliatic with focus on audit-readiness and GMP compliance.
Digitized 8 years of maintenance and calibration records
Established electronic workflows for work order approval and completion
Implemented rules-based calibration due date tracking with escalation alerts
Created equipment-specific maintenance procedures with built-in GMP checkpoints
Phase 3: Proactive Reliability (Month 5-6)
Transitioned from reactive firefighting to proactive equipment management.
Identified 34 pieces of critical equipment requiring enhanced monitoring
Optimized PM schedules based on actual equipment condition vs. calendar time
Reduced emergency maintenance events by 58%
Equipment-related deviations decreased from 12/month to 2/month
Phase 4: FDA Pre-Approval Inspection (Month 7)
Comprehensive inspection focusing on manufacturing operations and equipment systems.
Reduced equipment-related 483 observations
FDA inspector noted: 'Exemplary equipment management system'
Complete maintenance history for all critical equipment provided within minutes
Facility received manufacturing approval on first inspection
Annual Impact
$2.1M
Cost savings achieved
0
FDA 483 observations
99.8%
Critical equipment uptime
FDA-Ready Equipment Management
Our platform is built for the unique demands of pharmaceutical manufacturing, with deep expertise in GMP compliance and equipment qualification.