Introduction

In today’s fast-paced manufacturing environment, legacy systems can act as a significant bottleneck to operational efficiency, scalability, and innovation. This article explores how a major pharmaceutical manufacturer successfully modernized their outdated scheduling system using Ignition by Inductive Automation, creating a scalable and integrated platform that supports real-time insights and smarter decision-making.

Case Study: Modernizing a Scheduling System in Pharma

Background and Challenges

A large pharmaceutical company was struggling with a scheduling tool built in Excel. This system, which managed the timing and operation of sterilization machines supporting fill line operations, had become a source of growing frustration. It was slow, inflexible, and difficult to maintain, with limited ability to respond to real-time production needs.

Manual scheduling tasks were time-consuming and prone to error. The system could only support a limited scheduling window — just 12 to 16 hours at a time — due to the computing limitations of both Excel and the hardware it ran on. Compounding the issue was a lack of integration with the manufacturer’s MES and ERP systems, which made real-time updates nearly impossible. As production demands increased, the lack of scalability further exposed the system’s shortcomings.

What the company needed was a scheduling platform that was flexible, scalable, and accessible from anywhere — one that could support advanced scheduling logic, accommodate a longer planning horizon, and provide visibility and control over operations in real time.

The Solution: Ignition-Powered Scheduling System

To meet these goals, the company partnered with Sandalwood Engineering & Ergonomics Systems Integration Group to develop a web-based scheduling solution using Ignition. This new system represented a dramatic shift from the rigid, Excel-based workflows of the past.

Instead of manually inputting and manipulating scheduling data, the new platform could ingest production data directly from the MES and ERP systems. The scheduling algorithm was rebuilt from the ground up — abstracted from fixed inputs to allow greater flexibility and long-term viability. It was also designed with scalability in mind, allowing additional lines and products to be added with minimal rework.

Most importantly, the system enabled real-time reporting for both current operations and future production runs, delivering actionable insights across the organization.

Results and Business Impact

The benefits of this modernization were immediate and far-reaching. Manual scheduling processes were eliminated, which reduced data entry errors and saved countless hours of labor. The company could now plan production weeks in advance, a major leap from the previous 12–16-hour window.

Operators and planners gained real-time visibility into batch production schedules, improving responsiveness and ensuring compliance with stringent pharmaceutical regulations. Metrics for each machine’s schedule and performance were now readily available, providing operational clarity and empowering more informed decision-making. These reports became a core tool for dozens of users across a 24/7 operation.

The improved system also enabled better resource allocation—both in terms of equipment and personnel — leading to smoother operations, increased output, and fewer production disruptions.

Continuous Improvement and Next Steps

Modernization doesn’t end with the initial launch. After implementing the first phase of the solution, the team shifted its focus to refinement and expansion.

User feedback has led to interface improvements that make the platform even more intuitive. In parallel, work is underway to fully automate data ingestion from the ERP and MES systems via API calls, removing the final remnants of manual processes. The team is also exploring automated machine control, a powerful next step that, in the pharmaceutical space, must navigate strict regulatory pathways.

The ROI of Modernization

Financial Benefits

Let’s talk about dollars and cents — because at the end of the day, any business transformation must make financial sense.

One of the most immediate returns came from eliminating the inefficient, outdated systems that required constant workarounds. Teams were no longer burdened by the need to reconcile data manually between disconnected systems, which freed up valuable hours for more strategic work.

IT saw significant savings as well. Legacy platforms often come with high maintenance costs and require specialized expertise that’s increasingly difficult and expensive to find. In contrast, modern systems are easier to maintain and often offer more predictable licensing models.

Then there’s the issue of downtime — one of the most underestimated sources of lost profit. With more reliable infrastructure and built-in redundancies, the new system significantly reduced unplanned outages, leading to more consistent production and improved output.

Efficiency Gains

The shift to a modern platform also unlocked meaningful efficiency gains across departments. Access to real-time data meant teams could make faster, better-informed decisions. Instead of waiting on outdated reports or siloed spreadsheets, stakeholders could identify trends and resolve issues proactively.

The system also fostered collaboration across production, engineering, and management. With everyone working from the same source of truth, cross-functional alignment became easier, communication improved, and problem-solving became more effective.

Perhaps most importantly, automation of routine tasks reduced manual work, minimized human error, and improved overall data accuracy. As a result, employees could shift their focus toward more value-added activities.

Scalability and Future-Readiness

Future-readiness was a key consideration from day one. The new system isn’t just built for today’s needs — it’s built to evolve.

With an architecture that supports growth, the platform can be easily extended to additional production lines, facilities, or even global operations. It’s also designed to integrate with Industry 4.0 technologies, providing a foundation for advanced analytics, predictive maintenance, and other digital initiatives.

This kind of scalability ensures that the investment made today will continue delivering value for years to come.

Security and Compliance

For manufacturers — especially in regulated industries — security and compliance are non-negotiable. The modern Ignition-based system addressed these concerns head-on.

Centralized data management significantly improved the company’s cybersecurity posture, replacing fragile, outdated systems with a platform designed for today’s threat landscape. Rather than relying on patchwork security measures, the new solution incorporated best practices and security by design.

Compliance also became easier. The system could be configured to support FDA and ISO requirements, automatically enforcing standard operating procedures and simplifying audit preparation. The built-in traceability and auditability have also become key tools for continuous process improvement.

Conclusion

This case study demonstrates how a modern, Ignition-powered solution can replace legacy systems with something far more powerful — a scalable, real-time, and integrated platform that supports compliance, efficiency, and growth.

The transformation followed a clear path: understanding the pain points, envisioning the future, creating a phased implementation plan, executing it, and continually refining the solution. The result? A future-ready operation equipped to meet today’s challenges and tomorrow’s opportunities.

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