Digital Repair and Breakdown Management for Optimized Production Support in Vetter’s Cleanroom Operations

AI-generated / AI generated

AI-generated / AI generated

AI-generated / AI generated

Cleanrooms are among the most tightly controlled production environments. Prescribed gowning and disinfection steps, clearly defined airlocks, and logged entries are essential to prevent particles and microbes. Every entry – even for minor technical interventions on equipment – increases the risk of contamination and interrupts the process.

The consequence in day-to-day operations: The process is sensitive, time-consuming, and can affect production. Between gowning, coordination, and waiting times, valuable time passes while production personnel and equipment rely on rapid support from technicians.

How these challenges can be addressed through digital repair and breakdown management is demonstrated by Vetter’s practical example with the implementation of Maintastic maintenance software. The focus is on fewer cleanroom entries, structured collaboration and documentation, and efficient, cross-locational knowledge management.

Vetter Relies on Digital Processes

Vetter is one of the leading CDMOs (Contract Development and Manufacturing Organizations) specializing in aseptic manufacturing of injectable products. The family-owned business is headquartered in Ravensburg, Germany, employs over 7,000 people, and operates production sites in Europe and the United States.

To increase reliability in cleanroom operations, Vetter was looking for software tailored to the specific requirements of repair and breakdown management. At the end of 2024, the CDMO implemented Maintastic as a maintenance management solution.

The Situation Before Implementation

Vetter faced the following challenges in cleanroom production:

– Unnecessary cleanroom traffic: Various controlled zones must be passed before entering the cleanroom. Even for minor problems, technicians often had to be physically present in the cleanroom, which increased both the risk of contamination and the time required.
– Collaboration between multiple stakeholders: Information needed to resolve technical issues was spread across several stakeholders, including production personnel in the cleanroom, technicians in related production areas, and external machine suppliers. Coordinating all stakeholders was time-intensive and prone to delays.
– Efficient knowledge management: Limited access to equipment histories or previous service cases slowed knowledge sharing between departments and sites. As a result, resolving recurring technical problems became more difficult.

Process Improvements in Cleanroom Operations

To overcome the previously identified challenges and optimize cleanroom operations, Vetter uses the following Maintastic features:

– Live collaboration from inside the cleanroom: Through Maintastic, technicians can collaborate with production personnel in real time via video and chat. Augmented Reality annotations (AR), background blurring, and face anonymization support secure, context-rich communication.
– Centrally accessible solutions knowledge: Technical documentation of service cases is maintained in the integrated ticketing system. Each ticket is linked to the corresponding asset, is filterable, and enables finding and reusing completed solutions. Collected knowledge thus becomes more accessible to service teams across sites.
– Connection to the existing ERP system: Asset data, including equipment master records and technical location, is transferred one-way from SAP to Maintastic. SAP remains the authoritative source, while data consistency in operational support is ensured.

Implementation with Impact: Results in Cleanroom Production

Maintastic is now used daily by more than 350 professionals in production and maintenance. The following developments are visible in operations:

– Faster communication and higher equipment availability: Targeted collaboration shortens time to problem resolution. Avoiding unnecessary cleanroom entries saves 20 to 30 minutes per incident.
– Improved documentation and shared knowledge: Tickets include structured entries with images, videos, and comments. This increases data quality and supports knowledge transfer between production sites.
– Scalable, future‑ready platform: A second rollout phase is underway, bringing additional production personnel on board. Planned usage expansions include AI-supported voice input for incident reporting and modules for preventive maintenance.

Conclusion: Faster Response Times and Higher Availability

Introducing digital repair and breakdown management at Vetter has shortened response times and increased equipment availability. Fewer cleanroom entries and direct communication between production personnel and maintenance leads minimize time to the first effective action. Documentation in tickets and linking to assets makes solutions searchable and reusable. Overall, implementing Maintastic strengthens the ability to ensure reliable operation of critical production equipment, reduce downtime, and thereby support the continuous supply of vital medications.

Further information: https://maintastic.com/en/cmms-for-pharma-life-sciences/