LAPSE:2021.0762
Published Article
LAPSE:2021.0762
Analysis and Optimization of Two Film-Coated Tablet Production Processes by Computer Simulation: A Case Study
Stefanie Hering, Nico Schäuble, Thomas M. Buck, Brigitta Loretz, Thomas Rillmann, Frank Stieneker, Claus-Michael Lehr
October 14, 2021
Increasing regulatory demands are forcing the pharmaceutical industry to invest its available resources carefully. This is especially challenging for small- and middle-sized companies. Computer simulation software like FlexSim allows one to explore variations in production processes without the need to interrupt the running process. Here, we applied a discrete-event simulation to two approved film-coated tablet production processes. The simulations were performed with FlexSim (FlexSim Deutschland—Ingenieurbüro für Simulationsdienstleistung Ralf Gruber, Kirchlengern, Germany). Process visualization was done using Cmap Tools (Florida Institute for Human and Machine Cognition, Pensacola, FL, USA), and statistical analysis used MiniTab® (Minitab GmbH, Munich, Germany). The most critical elements identified during model building were the model logic, operating schedule, and processing times. These factors were graphically and statistically verified. To optimize the utilization of employees, three different shift systems were simulated, thereby revealing the advantages of two-shift and one-and-a-half-shift systems compared to a one-shift system. Without the need to interrupt any currently running production processes, we found that changing the shift system could save 50−53% of the campaign duration and 9−14% of the labor costs. In summary, we demonstrated that FlexSim, which is mainly used in logistics, can also be advantageously implemented for modeling and optimizing pharmaceutical production processes.
Keywords
3D simulation modeling and analysis, bottleneck analysis, model implementation, production costs, resource conservation
Suggested Citation
Hering S, Schäuble N, Buck TM, Loretz B, Rillmann T, Stieneker F, Lehr CM. Analysis and Optimization of Two Film-Coated Tablet Production Processes by Computer Simulation: A Case Study. (2021). LAPSE:2021.0762
Author Affiliations
Hering S: Department of Pharmacy, Saarland University, 66123 Saarbrücken, Germany; SW Pharma GmbH, 66578 Schiffweiler, Germany
Schäuble N: SW Pharma GmbH, 66578 Schiffweiler, Germany
Buck TM: SW Pharma GmbH, 66578 Schiffweiler, Germany
Loretz B: Helmholtz Institute for Pharmaceutical Research Saarland (HIPS), 66123 Saarbrücken, Germany [ORCID]
Rillmann T: SW Pharma GmbH, 66578 Schiffweiler, Germany
Stieneker F: Free Consultant and Qualified Person According to German Law, 79410 Badenweiler, Germany
Lehr CM: Department of Pharmacy, Saarland University, 66123 Saarbrücken, Germany; Helmholtz Institute for Pharmaceutical Research Saarland (HIPS), 66123 Saarbrücken, Germany [ORCID]
Journal Name
Processes
Volume
9
Issue
1
First Page
pr9010067
Year
2020
Publication Date
2020-12-30
Published Version
ISSN
2227-9717
Version Comments
Original Submission
Other Meta
PII: pr9010067, Publication Type: Journal Article
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LAPSE:2021.0762
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doi:10.3390/pr9010067
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Oct 14, 2021
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CC BY 4.0
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Oct 14, 2021
 
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Original Submitter
Calvin Tsay
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