PlantQuest implemented an advanced asset mapping solution seamlessly integrated into the client’s existing infrastructure and digital systems. The system provided:
- Comprehensive Asset Visualization: Covering multiple floors in two buildings, the solution enabled real-time tracking and visualization of all 663 assets (including 35 production bins, 34 scales, 30 pumps, 17 single-use mixers, 311 totes, and 150 calibration instruments). Users could instantly locate any asset on an interactive campus map with pinpoint accuracy.
- Dynamic Features: The platform delivered real-time updates and dynamic alerts for asset status changes (e.g., movement, idle time thresholds). Features like heat maps of asset utilization and historical movement trails allowed staff to analyze patterns and optimize asset distribution.
- Customizability: Tailored functionality was configured to meet each department’s needs. For example, EHS teams could track safety and calibration equipment compliance, while production teams received custom alerts for equipment availability. The solution’s flexible SDK allowed adding site-specific rules and tags without heavy re-coding.
- Scalability: A streamlined software development kit (SDK) and integration framework reduced code complexity. This design facilitated easy maintenance and future scaling—new assets or even new buildings can be added to the system with minimal effort, supporting the company’s growth and evolving Industry 4.0 initiatives.
The project began in Q1 2023 and was fully operational by April 2023 (a three-month turnaround). PlantQuest’s agile deployment approach ensured:
- Rapid Setup: Complete system setup, facility mapping for the two buildings, hardware installation (asset tags/sensors), integration with existing IT systems, and thorough testing were finished within the tight timeline.
- Minimal Disruption: Deployment was coordinated with site operations to avoid downtime. The rollout was phased to ensure no interruption to ongoing production – training and go-live occurred seamlessly without slowing manufacturing.
- Continuous Support: Post-implementation, PlantQuest provided ongoing support and monthly software updates. These iterative refinements were driven by user feedback and technological advancements, ensuring the solution remained optimized and aligned with Pfizer’s operational needs.
The integration of PlantQuest’s asset mapping solution delivered transformative results for the Sanford facility, providing both operational improvements and a clear return on investment (ROI):
- Operational Efficiency & Productivity Gains: The site achieved virtually zero wasted time in locating equipment. Staff no longer spend hours searching for missing totes or waiting on shared devices – freeing up an estimated 10+ hours per week that can be devoted to productive tasks. This improved efficiency has eliminated small production delays that used to accumulate, keeping batches on schedule.
- Cost Avoidance: By ensuring assets are easily found and optimally utilized, the facility avoided unnecessary replacement purchases and downtime costs. Missing or underutilized equipment is now a thing of the past. Estimated savings of $250,000+ per year have been realized through prevention of production stoppages and elimination of redundant asset purchases (since all 663 assets are accounted for and in rotation).
- Added Capacity: With better asset availability and no delays, the Sanford plant regained valuable manufacturing time. This translates into roughly 5% added capacity – equivalent to a few extra batches per quarter that the facility can now produce using existing resources. In other words, improved asset tracking unlocked additional throughput without capital expansion.
- Audit-Readiness & Compliance: The solution improved regulatory compliance by tracking calibration and safety assets in real time. Audit preparation is now simpler – all asset records and locations are digitally documented and easily accessible. The site can demonstrate full visibility and control over equipment usage and calibration status, reducing audit preparation time by 50% and ensuring audit-readiness on demand (a critical advantage in highly regulated pharma manufacturing).
- User-Friendly Integration: The introduction of interactive maps and intuitive navigation tools has boosted user adoption. Even non-technical staff find it easy to locate and manage assets via the visual interface, which means the solution is fully embraced across departments. This user-friendly design reduced training time and helped embed the new system into daily routines quickly.
- Streamlined Systems: The asset mapping platform simplified the IT landscape by consolidating multiple tracking spreadsheets and manual logs into one integrated system. This simpler, streamlined infrastructure reduces ongoing IT maintenance efforts and ensures that scaling up (to more assets or additional sites) is straightforward.
- Future-Proofing: The Sanford facility now has a robust digital foundation for future growth. The scalable PlantQuest system will allow easy integration of upcoming Industry 4.0 innovations – such as advanced analytics, IoT sensors, and predictive asset management. Sanford is also now connected as one of four Pfizer sites leveraging PlantQuest technology, creating a standardized approach to asset management across the company’s network. This positions the organization to share best practices and data seamlessly between facilities, and to expand the solution to additional sites with confidence.
Overall, the project delivered a mix of immediate operational benefits and strategic ROI. By combining cost avoidance (through reduced downtime and no redundant purchases) and productivity gains (through time savings and better utilization), the PlantQuest implementation at Pfizer Sanford has not only paid for itself but continues to add value. The site has gained added production capacity and strengthened compliance, all while establishing a scalable platform for the future. This successful deployment highlights how PlantQuest’s technology can drive efficiency and innovation in pharmaceutical manufacturing environments.
