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When one of India’s most prominent pharmaceutical manufacturers sought to modernize their plant automation, they needed more than just a SCADA system. They wanted complete visibility, improved efficiency, uncompromised quality control, and the flexibility to adapt to future needs.
AdiLogix SCADA was selected as the central nervous system of their operations — enabling real-time monitoring, secure data handling, intelligent alarms, and seamless integration with existing PLCs, instruments, and enterprise systems
The Client’s Challenges
Challenge
- Disconnected production & utility monitoring
- Manual data collection & reporting
- Multiple vendor systems with no integration
- Complex compliance requirements
- Limited historical analysis capabilities
Impact on Operations
- Delayed response to deviations, higher downtime
- Increased risk of human error, slow decision-making
- Inefficient workflows and duplicated effort
- Time-consuming audits, regulatory risk
- Missed opportunities for optimization
Our Approach
We started with a detailed plant study to map out all production, packaging, and utility processes. This included:
Identifying critical parameters for real-time monitoring (temperature, pressure, flow, batch timings, environmental conditions, etc.)
Designing a centralized SCADA architecture that covered production lines, cleanrooms, HVAC, water systems, and storage areas.
Ensuring compliance readiness for pharma regulations including GMP, WHO, and 21 CFR Part 11.
Planning integrations with PLCs from multiple vendors and the client’s MES system.
Defining KPIs to measure efficiency improvements post-deployment.
Results Achieved
Benefit
- 30% faster response time to deviations
- Centralized plant visibility
- Automated compliance reporting
- Improved product quality consistency
- Data-driven decision-making
Impact
- Reduced downtime and avoided production losses
- Better collaboration between production, maintenance, and QA teams
- Reduced audit preparation time by 70%
- Fewer deviations and rejections
- Identified optimization opportunities in process timing and energy use
