Case Studies

The next generation of digital manufacturing excellence in Biotech

The main goal for this global Biotech customer was to be at the forefront of biologic manufacturing. This greenfield facility was designed to be an inspirational Factory of the Future and ramp-up Biotech production capabilities in the US. As part of this revolutionary new build, the client wanted to reap the benefits of continuous manufacturing.

Training for an automated future

Building the best facility of its kind in the industry with state-of-the-art design, technology and processes, meant a business-critical training project had to be undertaken to upskill new and over 200 existing employees on the new DeltaV™ distributed control system (DCS).

Transitioning from paper-based records to digital manufacturing to improve data integrity

The client needed to replace its paper-based manufacturing records with a digital system at its facility in North Carolina. The company manufactures a range of products at the site including aerosols, tablets and dermatology products for treating respiratory and central nervous system diseases, HIV and anti-infective research.

Award Winning Managed Service

Zenith has successfully implemented and qualified major system upgrades including Pas-X and Honeywell and provided additional hypercare to ensure production was unaffected by each upgrade.

Deploying a global standard for weigh and dispense

Zenith worked with the client to deploy the solution for the first time at one of its key manufacturing sites in the U.S. The project was driven by the fact that the site was moving from a legacy ERP to a new standard SAP system. This move rendered the legacy weigh and dispense system and custom interface as obsolete.

Antibiotic Production Facility Benefits from Modernisation

One of the world’s largest pharmaceutical companies, needed to modernise its antibiotic production in the South East, USA. Since the antibiotic is no longer under patent, they needed to bring the new facility on line while rigorously controlling costs in order to successfully compete with generic drug manufacturers.

Justifying the Business Case for Implementing an MES System

Our client specialises in producing pharmaceutical products for eyes, medical devices, lasers and eye wear. Since witnessing steady growth and an acquisition the company wanted to move towards a company-wide implementation of SAP across all of it’s 21 sites in the USA, Europe and Asia.

Zenith put together a team of experts to provide a complete and impartial evaluation of the potential benefits of MES, with recommendations for solutions and a comprehensive implementation plan.

MES Centre of Excellence brings Standardisation and Productivity Improvements

A global pharmaceutical company with sites worldwide has a requirement to standardise their Manufacturing Execution Systems across four sites. In order to achieve this they wanted to create an MES Centre of Excellence (CoE) that would sit above all sites and provide leadership, best practices, research, support and training. The CoE needed to be tailored to the customer’s needs and flexible enough to work within a disparate configuration of the same MES platform.

New SCADA System Implementation and Network for Major Pharmaceutical Facility

Zenith experts designed and installed a complete SCADA (Supervisory control and data acquisition) system for the utilities at the plant. This included a data historian and an alarm system together with a highly resilient Hirschmann fibre optic data network linking the various production units.

Control System Upgrade from RS3 to DeltaV for Global Biotech Company

This case study is for one of the largest global biotech companies in the world, focused on the development and delivery of transformative therapies. With its main HQ in the US, the customer has been in operation for over 30 years and specialised in the class of rare genetic diseases. They approached Zenith Technologies with a requirement to migrate the existing Rosemount (RS3) control system within its manufacturing plant at Allston, Massachusetts to a more modern and efficient solution.

Serialization Project Rolled Out Across 20 Sites Worldwide for Multi-National Pharmaceutical Company

The Zenith Serialisation team began by working as a part of the client’s design team to develop an enterprise solution that would deliver serialisation functionality to its entire network. Once the design stage was completed, the team concentrated on the specifics by creating a test lab within one of the client’s facilities to validate the chosen serialisation solutions.

Standardising Manufacturing Across Multiple Plants With Managed Service Solution

A world leading pharmaceutical company with multiple production facilities in Ireland wanted to standardise manufacturing systems and work practices across multiple plants whilst achieving cost reductions and improvements in both efficiency and resilience.

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