Case Study: Global Pharmaceutical Company doubles production volumes with PA Consulting's smart manufacturing solutions

Doubling the production volume of medical devices

PA Consulting worked with a Global Pharmaceutical Company that produces medical devices and wanted to double production volumes within three years. The company had already explored several smart manufacturing technologies in an innovation lab, but needed help turning those ideas into practical improvements on the factory floor without disrupting production.

PA Consulting assessed more than 16 smart technologies and used pilots, agile delivery, and cross-functional teams to implement solutions such as machine learning, digital twin, remote diagnostics, and real-time performance visualisation. The result was a faster, more efficient production line that delivered £5 million in annual direct cost savings, avoided £200 million in capital spend, and generated a £50 million revenue uplift.