Helping Hikma Achieve Greater Efficiency with Digital Factory

Key Results

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Reduction in Changeover

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Increase in OEE

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Real-time Automated Reporting

Behind Hikma's Digital Transformation:

Success Story with SCW.AI

Digital Factory’s direct equipment integration and simple operator interface have supported our goals of using system data to focus on continuous improvement.

Matthew Burger

Director of Production

Hikma Pharmaceuticals, the second-largest pharmaceutical company in the MENA region by sales, is a $3B global generic pharmaceuticals manufacturing leader. It operates a diverse product portfolio supported by 30+ manufacturing facilities across six countries. This case study focuses on Hikma’s Columbus facility in Ohio, USA—a key site for its North America operations. Columbus facility specializes in the production of non-injectable products, including oral solids, liquids, nasal sprays, and inhalation therapies.

To strengthen operational agility and enable data-driven decision-making, Hikma Columbus partnered with SCW.AI. Through SCW.AI’s Digital Factory Platform, the facility has gained enhanced factory visibility, empowering teams with the real-time insights needed to optimize performance and improve manufacturing outcomes.

Scope

Hikma Columbus initiated its digital transformation to drive measurable improvements in OEE, downtime and performance metrics. The project scope encompassed 14 production lines across the compression, coating, and encapsulation departments. These lines were transitioned from an existing in-house digital system to SCW.AI’s Digital Factory Platform, for expanded features, real-time performance insights, and manufacturing analytics capabilities.

In parallel, an additional 7 production lines in the Wet Granulation department are currently in the onboarding phase. This phased rollout is designed to ensure seamless adoption and consistent performance improvements across departments.

Challenges

Before partnering with SCW.AI, Hikma Columbus faced several key challenges in advancing its manufacturing performance:

The need for a modern, user-friendly platform to support continuous improvement initiatives
Manual and time-consuming OEE tracking and reporting processes
Limited access to real-time, reliable production data for operators and managers
Gaps in decision-making due to fragmented visibility across production lines
A desire to foster a stronger culture of data-driven performance and accountability
Difficulty scaling existing systems to support cross-departmental agility

Solutions Implemented

To address its operational challenges and drive measurable improvements, Hikma Columbus implemented several key solutions in partnership with SCW.AI:

Deployment of the OEE Tracker: To reduce downtime, boost efficiency, and standardize performance monitoring
iPads installed on the shop floor: to enable seamless data input by operators and supervisors
TV dashboards: for real-time visibility into production performance, supporting faster response to issues
Integration with PLC/OPC systems: to enable automated, real-time monitoring of machine status and line conditions

Operational Change

Strengthened team accountability through real-time, transparent performance data
Improved data accuracy with direct machine-to-platform integration
Reduced manual data entry, allowing operators to focus on higher-value activities
Seamless integration into standard work routines and daily shift meetings
Reinforced a culture of operational excellence driven by data and continuous improvement

Business Benefits

The operational changes at Hikma Columbus, driven by digital capabilities and real-time data, yield the following outcomes:

12 percentage point increase in OEE, reflecting improved equipment utilization, reduced downtime, and enhanced operational efficiency
18% reduction in changeover time, enabling faster line readiness and increased production flexibility
100% automated reporting of factory issues and successes, eliminating manual reporting tasks and ensuring timely, data-driven insights for all stakeholders

Discover Hikma success story in our one-pager. Use it as your digital transformation inspiration.

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