Automating Pharma Supply Chains: How APS Makes It Easier to Plan, Produce, and Deliver

Over the past few years, pharmaceutical supply chains have come under growing pressure. Regulatory standards are tighter. Supply disruptions are more common. And there’s greater demand for speed, traceability, and flexibility—especially with the rise of personalized medicine and global distribution networks.

According to a recent McKinsey report, pharma manufacturers lose an average of 25–30% of production capacity due to planning and scheduling inefficiencies. In an industry where batch production is complex, materials are sensitive, and compliance is non-negotiable, these inefficiencies have real consequences: higher costs, delayed treatments, and regulatory risk.

That’s why more companies are adopting Advanced Planning and Scheduling (APS) tools to move away from fragmented, manual planning and toward connected, data-driven operations.

Pharma Supply Chains: Built to Be Resilient, but Hard to Run

Pharmaceutical manufacturing operates under a unique set of rules. Unlike other industries, pharma has to balance:

• Stringent regulatory compliance (FDA, EMA, GMP)
• Lot traceability and serialization
• Frequent audits and documentation requirements
• High cost of raw materials and wastage
• Short product lifecycles and growing demand variability

The Case for Automation

These challenges demand precision, transparency, and speed—qualities that manual processes can no longer support at scale. This is where automation steps in, offering:

• Real-time visibility across the supply chain
• Predictive insights for better decision-making
• Minimized human error
• Increased agility in responding to market fluctuations or disruptions
• Better collaboration across departments and with external partners

Yet, automation is most powerful when it connects the dots—linking planning, scheduling, execution, and analysis into a single, synchronized ecosystem.

What Is APS, and Why Does It Matter in Pharma?

Advanced Planning and Scheduling (APS) software is designed to improve production planning and scheduling through optimization and scenario modeling. In pharma, this can support:

• Multi-site production coordination

• Campaign scheduling to reduce cleanings and revalidations

• Batch tracking with expiry visibility

• Realistic production plans that account for labor, machine, and material constraints

• Regulatory documentation and traceability built into the planning process

Let’s say you have limited access to a packaging line and need to run multiple product types through it. APS can identify the optimal sequence that minimizes changeovers while still meeting delivery timelines—and flag any resource conflicts before they cause delays.

How APS and ERP/MES Integrations Make a Difference

Standalone tools help, but they don’t solve the full problem. Real transformation comes when APS tools like PlanetTogether are integrated with enterprise systems like:

• SAP ECC & S/4HANA

• Oracle EBS & Fusion Cloud

• Microsoft Dynamics 365

• Kinaxis RapidResponse

• Aveva MES

These integrations allow for live data exchange—so planners can see what’s actually available (materials, labor, equipment), track progress as production happens, and adjust schedules in real time.

Instead of spending hours gathering data and updating plans manually, teams get a single, connected view of what’s happening and what needs to happen next.

Practical Benefits of Automating with PlanetTogether + ERP Integration

Improved Scheduling Accuracy and Agility

Manual scheduling in Excel or disparate systems is prone to errors and lacks real-time responsiveness. With PlanetTogether pulling live data from SAP or Oracle, planners gain an accurate, up-to-date view of available resources and pending demands. This enables the creation of schedules that are both realistic and optimized—even in high-mix, low-volume production typical of pharma.

Reduced Downtime and Changeovers

Batch manufacturing often requires cleaning, sterilization, and revalidation between product runs. PlanetTogether automates campaign scheduling by grouping similar products to minimize these costly changeovers. Integrated with MES solutions like Aveva, the system ensures production execution aligns with the plan, reducing unplanned downtime.

Inventory Optimization and Expiry Management

Inventory carrying costs in pharma are high due to temperature control, expiry dates, and product sensitivity. By automating planning and integrating with ERP systems like Microsoft Dynamics or SAP, PlanetTogether enables just-in-time production, lowers WIP, and ensures materials are used before expiry—thus reducing waste.

Scenario Planning and Risk Mitigation

In the event of raw material delays, machine breakdowns, or regulatory holds, Supply Chain Managers need tools to simulate outcomes and evaluate alternate paths. PlanetTogether allows “what-if” scenario modeling based on real-time ERP data, helping managers to mitigate risk proactively.

Regulatory Compliance and Traceability

Automation doesn't just drive efficiency—it ensures repeatability and compliance. Integration with Kinaxis, for instance, helps create synchronized supply chain models that align with GMP practices. Every scheduling decision, batch traceability record, and inventory movement is digitally captured, facilitating smoother audits and documentation.

Real-World Impact: What Pharma Companies Are Seeing

Use Case Snapshot: Mid-Sized Pharma Manufacturer

A mid-sized pharmaceutical company manufacturing generic drugs was facing issues with schedule adherence, material shortages, and excessive overtime. Their planning process was fragmented between spreadsheets and SAP.

After integrating PlanetTogether with SAP, they achieved:

25% reduction in schedule delays

15% decrease in raw material holding costs

Enhanced visibility across procurement, production, and QA

Ability to run simulations for regulatory downtime and optimize campaign sequencing

This level of control was impossible with siloed systems. Automation through integration became a game-changer for operational stability and growth.

Final Thoughts: A Smarter Way to Plan and Produce

For Supply Chain Managers in pharmaceutical manufacturing, the push for automation is more than a trend—it’s a transformation. It’s about moving from reactive firefighting to proactive planning. From fragmented spreadsheets to unified platforms. From risk to resilience.

With PlanetTogether’s APS capabilities and its ability to integrate with platforms like SAP, Oracle, Microsoft, Kinaxis, and Aveva, automation becomes not just achievable, but scalable and sustainable.

The future of pharma supply chains is digital, integrated, and automated.  Are you ready to take your manufacturing operations to the next level? Contact us today to learn more about how PlanetTogether can help you achieve your goals and drive success in your industry.