How a Storeroom Relocation Cut Downtime by 65% in a Pharmaceutical Plant
the project overview
Project Type: Relocation and expansion of an existing storeroom
Location: Sweden
Service: MRO Storeroom Relocation & Optimization
Efficient MRO management is crucial for minimizing downtime in the highly regulated pharmaceutical industry. Companies must walk the tight rope between ensuring compliance and maintaining production. This is especially true when it comes to upgrading facilities or processes as part of any Continuous Improvement initiatives.
The Challenge
The client’s existing MRO storeroom was located outside a controlled non-classified (CNC) area, adjacent to a sterile cleanroom environment. Every time a technician needed a spare part:
- They had to fully remove PPE, walk to the storeroom, retrieve the part, then re-suit to re-enter the cleanroom.
- This repeated process led to significant delays in maintenance resolution.
- The costs of constantly replacing PPE (masks, suits, gloves) added up quickly.
- The main storeroom was also centrally located far from the production lines, adding unnecessary travel time.
Key Pain Points:
- Lost productivity due to WALK AND WAIT and dressing time.
- Elevated operational costs due to repeated PPE changes.
- Increased risk of prolonged downtime during breakdowns.
The Solution
RS Integrated Supply conducted a comprehensive analysis of a year’s worth of storeroom withdrawals. By classifying critical spares and quantifying downtime related to parts retrieval, they discovered:
- Over 350 hours of lost productivity annually, equating to nearly £726,000 (USD $820,000) in potential production losses.
The data supported a strategic storeroom relocation inside the cleanroom environment, drastically cutting down travel time and eliminating the need for repeated PPE changes. The new plan also accounted for compliance with stringent pharmaceutical cleanroom standards.
Implementation
Over 5,000 MRO items were cataloged, picked, packed, and transferred without disrupting ongoing production. RS Integrated Supply leveraged existing conveyor systems for efficient movement, while coordinating closely with the client’s quality team to ensure regulatory compliance.
Key highlights of the implementation:
- Strategically relocated storeroom within the sterile zone
- 65% efficiency gain in technician walk-time reduction
- Enhanced accessibility to critical spare parts
- Safe, ergonomic storage solutions for larger equipment
result
The relocation resulted in a 65% reduction in travel time for technicians, improving maintenance efficiency and significantly reducing unplanned downtime. The new storeroom setup also minimized PPE waste, improved safety, and supported the client’s Continuous Improvement goals.
Business Impact at a Glance:
- 350+ hours of annual downtime eliminated
- £726,000+ (est. USD $820K) in estimated production cost savings
- Improved technician efficiency and response time
- Enhanced compliance and safety in cleanroom operations
By aligning MRO strategy with operational realities in a sterile pharmaceutical environment, RS Integrated Supply delivered a smart, scalable solution that drives performance, reduces waste, and supports long-term reliability. This project serves as a benchmark for pharmaceutical companies seeking to optimize MRO in high-compliance settings.
