P harmaceutical manufacturers and distributors are continuously being challenged to increase output while improving operational efficiency as automation in the pharmaceutical industry increases . Strict quality and safety standards are synonymous with this industries ’ culture and DNA . With these strict requirements , manufacturers and distributors must pay close attention to all details in the production and distribution process , making inventory management a key element in reducing the risk of product recalls and protecting consumers .
While the medical professionals who administer pharmaceuticals are aware of how sensitive certain drugs can be to temperature changes , warehouse workers may be less familiar with the delicate nature of these drugs . Their main concern is ensuring the product is delivered to the customer on schedule , which can result in unrecognized mistakes in procedure or damaged product . For this reason , good warehouse practices in the pharmaceutical industry are imperative . Clearly defined procedures and responsibilities are key to ensuring that biologics , drugs , and other pharmaceuticals arrive ready to be used .
Pharmaceutical companies are turning to fully automated warehouse solutions to meet the industry ’ s strict requirements and internal operational challenges , creating pharmaceutical storage solutions that benefit them . Warehouse automation provides real-time insight for quality control without the need for human contact with the substances that are being manufactured . This greatly reduces the risk of contamination and improves employee safety .
Some pharmaceutical companies require their product to be stored in very cold environments ( i . e . blood plasma ). Automation in these environments reduces the opening and closing of large forktruck doors and utilizes properly designed vestibules to eliminate frost and contamination . This stabilizes temperatures , reducing energy costs and the risk of product damage . An automated system doesn ’ t have to take breaks to warm up , increasing pick speeds and overall throughput .
To implement traceability , pharmaceutical wholesalers are currently encountering a variety of issues , from an increase in the costs of machines that trace information like ingredients and place of origin ( and then recording it ), to a reduction in picking fulfillment rates , as each unit must be scanned individually . This process has become even more complicated as a result of current technology constraints when scanning GS1 codes , as each scan takes longer to complete per item , especially when compared to a RF scan of a ID bar code . Additionally , the packaging that wraps around the GS1 bar codes can create mis-reads , which reduces the speed of information collection .
However , AS / RS solutions are proving to significantly enhance the scanning process and ensure 100 % accuracy by making the picking , identification , counting and checking processes easier . In addition , smart warehouse solutions result in increased storage space utilizing higher storage capacity per cubic foot while simultaneously enabling dynamic inventory organization and delivering high picking accuracy .
The layout of a warehouse is key to its efficient operation . In developing warehouse or distribution center layouts , pharmaceutical corporations face unique challenges due to the nature of their products . Pharmaceuticals are sensitive not only to external contamination from bacteria or chemicals but also to temperature changes . In some cases , even lighting can damage pharmaceuticals . Pharmaceuticals must also be stored in a way that makes it easy to use a firstin , first-out system keeping these critical and expensive products safe from theft and deliberate contamination . These unique requirements mean that many factors need to be considered when setting up a warehouse for pharmaceutical storage – making it more important than ever to work with a verified , experienced automation partner .
CASE STUDY : Grifols
Grifols is a global healthcare company producing life-saving protein therapies and products in three healthcare divisions : bioscience therapy made from human plasma , hospital products and pharmacy IV solutions , and diagnostic tools for laboratory professionals .
Their new plasma logistics center in Clayton , N . C . handles the cold storage ( -35C ) of plasma blood products , the suitability inspection of plasma units according to tight quality standards and the shipment of frozen plasma via truck and / or ocean container to the Grifols ’ manufacturing plants .
Westfalia installed an AS / RS , combined with Savanna . NET Warehouse Execution System ( WES ), to support Grifols ’ continued innovation in its modern , state-of-theart facilities . The AS / RS occupies 17,273 square feet with 5,148 pallet positions .
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