Discrete Event Simulation Modelling for Dynamic Decision Making in Biopharmaceutical Manufacturing

With the increase in demand for biopharmaceutical products, industries have realised the need to scale up their manufacturing from laboratory-based processes to financially viable production processes. In this context, biopharmaceutical manufacturers are increasingly using simulation-based approaches to gain transparency of their current production system and to assist with designing improved systems. This paper discusses the application of Discrete Event Simulation (DES) and its ability to model the various scenarios for dynamic decision making in biopharmaceutical manufacturing sector. This paper further illustrates a methodology used to develop a simulation model for a biopharmaceutical company, which is considering several capital investments to improve its manufacturing processes. A simulation model for a subset of manufacturing activities was developed that facilitated ‘what-if’ scenario planning for a proposed process alternative. The simulation model of the proposed manufacturing process has shown significant improvement over the current process in terms of throughout time reduction, better resource utilisation, operating cost reduction, reduced bottlenecks etc. This visibility of the existing and proposed production system assisted the company in identifying the potential capital and efficiency gains from the investments therefore demonstrating that DES can be an effective tool for making more informed decisions. Furthermore, the paper also discusses the utilisation of DES models to develop a number of bespoke productivity improvement tools for the company.