From Paper to Digital: Modernizing a National Vitamin Manufacturer
The Challenge
A leading national vitamin manufacturer struggled with outdated, paper-based systems to manage production records, quality control, and regulatory compliance. This manual approach caused:
- Delays in data entry, verification, and reporting
- Difficulty identifying quality deviations across facilities
- Disconnected recipe management, reducing standardization
- Operators focusing more on paperwork than production
- Lengthy and inefficient compliance audits
- Limited real-time visibility into production and material usage
While the company utilized SAP for enterprise resource planning, factory floor operations remained siloed. To remain competitive and meet FDA and international standards, the company needed a modern manufacturing execution system (MES) to bridge the gap between enterprise and shop floor operations.
The Solution
The company partnered with us to implement a MES platform that connected their factory floor to their enterprise systems. Key features included:
- Digital Batch Records – Automating batch creation, tracking, and electronic approvals
- Process Sequence Management – Standardizing workflows with built-in verification steps
- Core MES Integration – Real-time connectivity between SAP and production activities
- Mobile Factory Tools – Enabling operators to document processes digitally on the floor
- Electronic Signatures – Supporting digital approvals to meet compliance requirements
- Real-Time Dashboards – Providing live visibility into KPIs, production status, and material usage
The rollout started at a pilot site and later expanded to multiple facilities.
The Results
- Accelerated access to production data
- Improved plant-wide operational efficiency
- Stronger regulatory compliance with digital audit trails
- Reduced manual paperwork and errors
- Increased batch record accuracy and real-time traceability
- Better decision-making with live operational visibility
Pablo Villalpando
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