Vaccine Manufacturer Expects €10M+ in Annual Economic Value with AI Predictive Maintenance
Value-Driven Benefits
€10M+
estimated annual economic benefit with C3 AI Reliability deployed across 40+ assets at each facility
200+
machine learning models configured, trained, and evaluated to determine the best-performing model
12 weeks
to initial production deployment across two facilities
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Introduction
A major biopharmaceutical company operates advanced manufacturing facilities for vaccines and biologics medicines across multiple continents. To drive continuous improvements in production efficiency, the company sought to implement AI solutions aimed at reducing unplanned downtime — a key contributor to costly product discards and manufacturing disruptions.
Challenges
In pharmaceutical manufacturing — particularly for vaccines and biologics — equipment reliability is essential to maintaining both production output and product quality. Failures can lead to delays, batch losses, and resource-intensive investigations. However, prior to engaging with C3 AI, the company relied on traditional and rigid time-based maintenance strategies and lacked both integrated data access and the tools needed to predict emerging downtime risks. These challenges led to excessive interventions, extended turnaround times, and difficulties in scaling production efficiently.
Solution
To address these challenges, the company partnered with C3 AI to implement an AI-driven predictive maintenance application, C3 AI Reliability, at two lighthouse facilities in Canada and Belgium. Within 12 weeks, the team deployed C3 AI Reliability at the two sites — reducing deployment time at the second Belgian facility to just 4 weeks, unified previously siloed data, and configured out-of-the-box machine learning models to predict emerging downtime risks and deliver prioritized, explainable alerts for engineers.
Results
By shifting to an AI-enabled, predictive maintenance approach with C3 AI Reliability, the company expects to realize an estimated annual economic benefit of over €10M per facility. Building on the success of the initial deployment, the company is expanding its partnership with C3 AI and scaling C3 AI Reliability deployment to additional facilities and a broader set of assets.
About the Company
- €40+ billion in annual revenue
- 4.8+ billion units of medicine, vaccines,
and healthcare products produced annually - 170+ countries served
- 90,000+ employees
Project Highlights
- 12-week initial production deployment
to two facilities - 4-week deployment timeline for the
second site - 200+ AI/ML models developed, trained,
and evaluated - 400+ time-series tags integrated across
assets at two sites - C3 AI Reliability application user interface
configured - 14 users trained
Solution Architecture
Proven results in weeks, not years
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