Optimization of a Portable Passivation Skid in Manufacturing Operations

Abstract

The limited internal utilization of a portable passivation skid in a biopharmaceutical manufacturing facility resulted in reliance on outsourced passivation services, increasing operating costs. This project applied a structured Define – Measure – Analyze – Improve - Control methodology to quantify the economic and operational impact of contractor executed passivation and to evaluate internal execution alternatives within a three-month project window. Baseline analysis demonstrated that contractor executed passivation events incurred significantly higher costs than internally executed activities, even when internal support labor was considered. Cost–benefit evaluation by passivation type identified recurring heat exchangers and a 500-liter tank as high impact candidates for internal execution. Results showed that internal passivation reduced per event costs by approximately 80% for the heat exchangers and by more than 70% for the tank. The primary constraint limiting internal passivation was economic dependence on external contractors rather than technical capability. Key Terms ⎯ cost-benefit analysis, outsourcing reduction, preventive maintenance strategy, process standardization.