Zydus Wellness - Optimizing Maintenance Operation and Resolving Manufacturing Challenges with Cryotos (CMMS)

Challenges Before Cryotos (CMMS) Implementation

Before the Cryotos system was integrated into their manufacturing process, Zydus Wellness faced a range of operational difficulties that hindered production efficiency and impacted their production output. These challenges included:

1. Unexpected Downtime and Equipment Failures
   Zydus Wellness frequently experienced unexpected equipment downtimes, which disrupted their production schedules. These downtimes were often unplanned and unpredictable, leading to significant production delays and increased operational costs.
2. Unscheduled Machine Repairs
   The company faced frequent instances of unscheduled repairs, as machines would often break down without prior warning. This unplanned maintenance resulted in unproductive periods, slowing down the overall manufacturing process.
3. Maintenance Delays
   The maintenance team often struggled to respond quickly to equipment failures or breakdowns, further compounding the impact of unexpected downtimes. These delays affected the timely resumption of operations, resulting in additional delays and cost overruns.
4. Inconsistent Calibration
   The manufacturing processes at Zydus Wellness required precise calibration to ensure that machines functioned optimally. However, inconsistent calibration led to equipment malfunctions, and variations in product quality, thus affecting overall productivity.
5. Lack of Provisions for PM and Breakdown Management
   Critical machines such as Autoclave, Axiomatic, Bag Dump, Bin Blender, Blister Machine, Checkweigher, and PCS Compression were operating without adequate provisions to handle Preventive Maintenance (PM) and Breakdown management. Without clear procedures and tracking, these machines were prone to failure, which further complicated the overall manufacturing process.
6. Inability to Track Downtime and Conduct Root Cause Analysis
   One of the significant pain points for Zydus Wellness was the inability to track the root causes of downtime events. It was difficult to identify whether downtime was caused by electrical or mechanical issues, making it challenging to address the underlying problems. As a result, repeated failures occurred without an understanding of their source, preventing proper remediation.

Impact on Operations

These operational challenges created a ripple effect throughout the entire manufacturing process at Zydus Wellness:

• Increased Operational Costs: The inefficiencies caused by unplanned downtime, unscheduled repairs, and maintenance delays led to increased operational costs. Additionally, the inconsistent calibration and breakdowns resulted in costly repairs and maintenance, driving up overall expenditure.
• Disrupted Production Schedules: Unpredictable downtime and delays in maintenance disrupted production schedules, resulting in missed deadlines and delayed product deliveries. This negatively impacted Zydus Wellness' ability to meet customer demands and maintain a consistent supply of products to the market.

Cryotos Implementation: The Transformation

To address these issues, Zydus Wellness integrated Cryotos, a sophisticated equipment management and predictive maintenance solution, into their operations. The Cryotos system helped to optimize maintenance processes, track equipment performance, and ensure better machine reliability, ultimately enabling Zydus Wellness to:

• Prevent Downtime: Cryotos enabled the team to prevent potential equipment failures before they occurred. By analyzing data from machines in real-time, the system provided early warnings of potential issues, allowing for proactive maintenance and reducing unexpected downtimes.
• Streamline Repair Scheduling: Cryotos allowed Zydus Wellness to schedule repairs more efficiently by providing visibility into machine performance. The system’s predictive capabilities ensured that repairs could be planned in advance, reducing unplanned maintenance events.
• Enhance Maintenance Timeliness: With Cryotos, the maintenance team could be alerted in real-time about failing equipment. This improved their ability to respond quickly, reducing delays in maintenance and allowing operations to resume faster.
• Ensure Consistent Calibration: Cryotos helped Zydus Wellness monitor and calibrate machines with greater precision. The system allowed for continuous calibration checks, ensuring that machines operated at peak performance and producing high-quality products consistently.
• Track Downtime and Identify Root Causes: With Cryotos’ tracking and reporting features, Zydus Wellness was able to identify the root causes of downtime events, whether mechanical or electrical. The system categorized these issues and provided detailed reports, helping the team make informed decisions for corrective action.

Key Features and Benefits:

• Downtime Tracking
• Categorization Based on Issue Type
• Planned vs. Actual (Scheduled Maintenance)

Key Benefits of Cryotos for Zydus Wellness

• Reduced Downtime: With early alerts on equipment malfunctions and predictive insights, Zydus Wellness significantly reduced unplanned downtime. This not only improved production efficiency but also ensured that critical products reached customers on time.
• Cost Savings: By addressing issues before they led to major breakdowns, Cryotos helped Zydus Wellness save on costly repairs and replacements, contributing to long-term savings in maintenance costs.
• Improved Equipment Lifespan: Regular and precise monitoring of key equipment components ensured that machines like the Autoclave, Weighing Machines, and PCS Compression Machines operated efficiently, extending their lifespan and improving return on investment (ROI).
• Optimized Maintenance Schedules: Cryotos’ predictive maintenance algorithms allowed Zydus Wellness to optimize maintenance schedules, ensuring that resources were used effectively and reducing the frequency of unnecessary maintenance activities.
• Improved Product Quality: By ensuring equipment runs at peak performance, Cryotos helped Zydus Wellness maintain high-quality production standards, minimizing the risk of defects caused by malfunctioning machines.