Dr. Reddy’s Laboratories is one of India’s largest pharmaceutical manufacturers. Its multiple certified manufacturing plants around the world produce patient-ready medications, active pharmaceutical ingredients (APIs), diagnostic kits, critical care and biotechnology. The group recently had its largest smart manufacturing facility recognised as part of the World Economic Forum’s Global Lighthouse Network, for showing leadership in applying Industry 4.0 technologies.
AVEVA PI System is key to its digital transformation strategy, contributing to its nearly 90% improvement in productivity, as well as improvements that have reduced quality-related costs by 40% at its flagship manufacturing site. AVEVA PI System also aligns with the group’s ambitions to optimize energy use, reduce emissions and become 100% paperless by 2030.
“PI System is central to ensuring we have real-time streaming analytics capabilities, so that we actually monitor the process behavior on the product through… defined specification limits. One thing that stands out for me in our relationship with AVEVA, is the interest that the PI team that works with us has to ensure that customer success is actually what is driving the relationship.”
Srihari Kaninghat, Head of Digital and GM Technology, Dr. Reddy’s Laboratories
Goals
- Continue to improve costs, productivity and quality
- Become even more sustainable by reducing scope 3 emissions, improving energy management, reducing discharges into landfills and implementing 100% paperless operations by 2030
Challenges
- Improving overall equipment efficiency and cost expenditure
- Increasing equipment reliability and minimizing losses associated with downtime (batch failures)
- Digitizing site-wide operations and reducing manual paper-based outputs
Solution
Results
- Recognized by the World Economic Forum as a smart manufacturing lighthouse
- Reduction in quality-related costs by 40%
- Nearly 90% improvement in productivity
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