Lifetime Efficiency
Focusing on the potential instead of the problem

Even proven production processes still hide some untapped potential. In the form of Lifetime Efficiency, Fette Compacting has developed an approach which enables pharmaceuticals companies to release hidden efficiency reserves. Rainer Krugmann and Lars Plüschau explain how this works.

Mr. Krugmann, Mr. Plüschau, what is the main idea behind Lifetime Efficiency?
Rainer Krugmann: The idea is that we work with our customers to discover their untapped potentials. We not only examine whether machinery is running but also extend our focus to include the entire life cycle of their plants and products to increase efficiency – hence Lifetime Efficiency.
Lars Plüschau: We want to support customers by offering them comprehensive analyses of their solid formulation production and systematically improving their processes. This represents a change in perspective – focusing on the potential instead of the problem. Potentials lead to concrete solutions and gain even closer loyalty of customers.

What specific changes are there for customers?
Rainer Krugmann:Collaboration with customers used to concentrate on handling problems and requirements. But that is not the type of partnership we strive towards with Lifetime Efficiency. Now, we collaborate on site much more intensively, talking to everyone involved, and taking a very close look at promising areas. Only this way can we find savings potentials which are truly extensive, whereby we rely on experience gleaned from thousands of installations worldwide.
Lars Plüschau: It is also important that we include all perspectives from the customer’s point of view. We talk to the shop floor and top management in an effort to obtain an overall picture. This enables us to reliably detect the potentials and provide specific proposals for solutions which take consideration of all facts for possible investment decisions.

What potentials are involved and how high are they?
Lars Plüschau: The potentials can become visible in entirely different areas. While one customer may benefit from higher output due to optimal tableting tools or an improved tablet design, another customer may benefit from reduced profit losses and yet another from a leaner spare parts store – or even all of these factors together. Accordingly, gross savings can vary from one case to another.
Rainer Krugmann: : As the interplay of influential factors is so complex, the Lifetime Efficiency system is enormously helpful. Sometimes we are even surprised of the extent of savings potential which can, in fact, reach the tens of millions.

Does this oblige manufacturers to disclose their entire operations?
Lars Plüschau: Not at all. But we cannot progress without machine and process data. The customer decides on the extent of disclosure. The greater the trust, the sooner the customer involves us, and the longer he retains our support, the more he will benefit in the end – in terms of both money and time saved.

Who can utilize Lifetime Efficiency?
Lars Plüschau: Anyone. This new type of cooperation is open to all customers. What is important is that they develop an awareness of how high the value-added potential can actually be in production. This awareness has increased markedly among many of our customers.
Rainer Krugmann: This is equally applicable for researching pharmaceuticals manufacturers and producers of generic drugs. Originators count on maximum production reliability and quality accompanied by minimum product loss which is what Lifetime Efficiency is based on. Producers of generic products are driven by reducing the costs per tablet or capsule – areas which also harbor significant potentials.

And what changes does this mean for Fette Compacting?
Rainer Krugmann: We intensify our already close collaboration between Sales and Service as well as improve coordination of our customer management. As a team, we are now capable of swiftly detecting where our customers can achieve the highest savings. This skill improves with each new and individual case.

More information can be found here: Lifetime Efficiency.