Improving industrial production efficiency and streamlining production process monitoring is more crucial than ever for modern manufacturers. Yet, achieving these goals requires a step-by-step, scalable strategy that doesn’t disrupt existing operations.

In this article, we explore how a leading pharmaceutical company leveraged Zerynth’s Manufacturing Intelligence Platform to launch a continuous improvement journey—enhancing efficient production, identifying machine downtimes, and optimizing production process efficiency.

Keep reading to discover how they did it.

Industry Challenges

A prominent pharmaceutical manufacturer, already equipped with MES and ERP systems, turned to Zerynth to gain deeper, real-time insight into their shop floor operations.

Their goal? Drive efficient production by increasing output volumes, improving the performance of both auxiliary and primary machinery, cutting down on waste, and reducing errors caused by manual processes.

Even with a solid technological foundation, the company faced challenges in managing and analyzing production data. Limited visibility into auxiliary equipment made production process monitoring complex, and interpreting data in an intuitive, actionable way was nearly impossible.

To make matters more complicated, the facility operated with a mix of old and new equipment—ranging from electromechanical machines to modernized (revamped) systems—which required a unified approach to ensure seamless communication. On top of that, employees needed to be trained to use an on-premise platform without disrupting daily production and to easily interpret the data they had at their disposal.

The Solution

To overcome these challenges, the company partnered with Zerynth through a structured consulting approach. The journey began with an in-depth analysis of both machinery and workflows to identify key improvement areas and define the most relevant KPIs.

Zerynth’s Manufacturing Intelligence Platform enabled real-time data collection, giving the company a clear, always-updated view of operational performance.

One of the most valuable aspects of this implementation was Zerynth’s ability to turn raw data into actionable insights—enhancing production process efficiency and optimizing how the production lines operate. Constant, structured production monitoring allowed Zerynth experts to provide tailored advice for continuous improvement, ensuring targeted and effective control over operations.

The platform gave the company instant visibility into key KPIs such as machine setup times, production cycles, cycle durations, and costs and energy consumption per task. Manual data entry was eliminated in favor of fully automated data acquisition, drastically reducing errors and improving operational accuracy.

The seamless integration of machines from different generations—including newly designed systems, revamped equipment, and legacy electromechanical machinery—allowed the company to connect all production assets under one roof. This eliminated inefficiencies caused by managing heterogeneous technologies.

The Results

By adopting Zerynth’s production monitoring solution, the company achieved a remarkable 25% reduction in operational costs—thanks to improved control, better visibility, and real-time data access.

Waste was reduced by 10%, driven by smarter management of downtime and increased production process efficiency.

And by eliminating manual input and streamlining operations, human error decreased by 20%.

Why Choose Zerynth to Improve Industrial Production Efficiency?

Zerynth delivers a scalable, customizable solution that adapts to the specific needs of each industry. The real value lies in the step-by-step implementation approach, allowing businesses to gradually integrate the platform without disrupting productivity.

By combining cutting-edge technology with expert consulting, Zerynth transforms data into a strategic asset at the core of decision-making.

In this case study, real-time insights empowered the pharmaceutical company to gain control over its operations, reduce downtime, and enhance production efficiency in a sustainable way.

Zerynth’s platform marked the beginning of a continuous improvement journey—turning data into a growth driver for innovation and long-term competitiveness.

Want to see how Zerynth can help you unlock efficient production with a tailored, scalable path? Let’s talk.