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Pharmaceutical Manufacturing

Pharma Grade.
FDA Ready.

Pharmaceutical manufacturing demands the highest standards of equipment integrity and documentation. Reliatic delivers GMP-compliant asset management with complete audit traceability.

Current Deployment Scale
16
Facilities
Audit-ready
FDA-aligned
Low
483 Findings

Pharma Manufacturing Challenges

FDA inspections, equipment qualification, and complete documentation traceability are non-negotiable in pharmaceutical manufacturing.

GMP Compliance & 21 CFR Part 11

The Challenge

Pharmaceutical equipment must maintain complete documentation of all maintenance, calibration, and modifications. Manual record-keeping creates gaps that trigger FDA 483 observations and warning letters.

How Reliatic Solves It

Reliatic provides 21 CFR Part 11 aligned electronic records with full audit trails. Every change is timestamped, user-attributed, and tamper-evident. Electronic signature workflows and reason-for-change documentation are built-in.

Real Result

API manufacturing facility passed a comprehensive FDA inspection with improved equipment traceability and audit readiness.

Equipment Qualification Lifecycle

The Challenge

IQ/OQ/PQ documentation is often scattered across paper files, shared drives, and individual computers. Re-qualification schedules are tracked manually, leading to lapses that compromise validation status.

How Reliatic Solves It

Centralized qualification management with rules-based re-qualification alerts. Links calibration records, change controls, and preventive maintenance to qualification status. Regularly refreshed validation dashboards show equipment fitness.

Real Result

Biologics manufacturer reduced qualification documentation time. Alerts helped reduce qualification lapses that would have required expensive re-validation.

Critical Utilities Reliability

The Challenge

Clean steam, purified water, and HVAC systems are critical utilities that directly impact product quality. Traditional reactive maintenance risks contamination events and batch losses.

How Reliatic Solves It

Condition-based maintenance for critical utilities with scheduled monitoring integration. Track water quality trends, filter differential pressures, and heat exchanger performance. Risk-based inspection prioritizes critical equipment.

Real Result

Injectable manufacturing site eliminated 4 utility-related deviations per year. Water system sanitization intervals optimized based on bioburden trending, saving $180k annually.

Sterile Processing Integrity

The Challenge

Autoclaves, isolators, and clean-in-place (CIP) systems require meticulous maintenance records. Any equipment failure in sterile processing can compromise entire production batches worth millions.

How Reliatic Solves It

Specialized maintenance protocols for sterile processing equipment. Tracks steam penetration tests, biological indicators, and seal integrity. Integrates with batch records to establish equipment-product correlation.

Real Result

Sterile manufacturing facility achieved 99.8% critical equipment availability. Proactive seal replacement prevented 2 autoclave failures that would have scrapped $4.2M in product.

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.

Reliatic — Asset Integrity Governance Platform