The challenge involved optimizing the production capacity for a global pharmaceutical glass manufacturer, during the COVID-19 pandemic. With a sudden surge in demand for glass vials to package vaccines, the company faced capacity constraints at its prime facility. 

To solve this, we were given two days to develop and present a solution. my team and I built an optimized strategy to identify inefficiencies, analyze bottlenecks, and propose improvements in the supply chain. 

We developed an advanced linear optimization model using Excel and the Solver tool to calculate the best production and allocation numbers. 

Our solution prioritized the production of COVID-19 vaccine vials while ensuring a steady supply of other critical vaccines. By addressing these bottlenecks and aligning priorities, we provided actionable recommendations to help the company navigate the surge in demand effectively. 

Why is this Important ?

This challenge highlights the importance of balancing demand and capacity during sudden surges. In real-world supply chains, inefficiencies and bottlenecks can lead to lost revenue and customer dissatisfaction. Optimizing resources and prioritizing production ensures critical demands are met, disruptions are minimized, and operations remain resilient and profitable. 

In 1973, a toilet paper shortage made headlines, and more recently, semiconductor shortages have disrupted industries worldwide. These challenges underscore the critical need for every manufacturing and supply chain to be optimized and efficient to handle unpredictable demand surges effectively. 

Take a look at our solution below:

Approach we took

We started by analyzing the process in detail, studying the data exhibits and supply chain information provided. We identified key bottlenecks that were affecting capacity and efficiency. Based on this analysis, we made necessary assumptions and defined success metrics to guide our optimization. 

How we solved the problem

Using Excel, we built a linear optimization model that incorporated these constraints and assumptions. We then used the Solver tool to run different scenarios and identify the optimal production plan, which would help maximize capacity utilization while ensuring the demand for COVID-19 vaccine vials and other critical vaccines were met. 

Results

We won the competition by delivering the best optimized solution, maximizing production capacity and meeting the increased demand for COVID-19 vaccine vials while ensuring no disruption to other critical vaccine supplies. 

The efficiency of our strategy impressed the judges, securing us first place in the competition. 

Later, I was contacted and offered the opportunity to work as a Teaching Assistant for a graduate course related to this concept. I also had the privilege of collaborating with the Dean of the School of Business and Operations Research expert Gregory P. Prastacos, who is also the former CEO of Deloitte Greece.