Pharmaceutical Online Covers Chugai Pharmaceutical Co., Ltd., Pharmaceutical Honorable Mention FOYA Selection
27 July, 2026
Chugai Pharmaceutical is leveraging a highly integrated digital infrastructure at its FJ3 active pharmaceutical ingredient (API) manufacturing facility to support automation, data-driven decision-making, and long-term operational flexibility. The facility, which recently received Honorable Mention recognition by the 2026 ISPE Facility of the Year Awards (FOYA) program, was designed not only with advanced automation in mind but also with a digital backbone capable of connecting systems, streamlining workflows, and enabling continuous improvement.
At the heart of Chugai’s strategy is the seamless integration of enterprise and manufacturing systems across the facility. The company has linked its enterprise resource planning (ERP), manufacturing execution system (MES), warehouse management system (WMS), and distributed control system (DCS) to create a fully connected and paperless manufacturing environment. Chugai uses SAP as its ERP platform, serving as the central source for planning activities and master data management. The MES acts as the operational hub for production execution, collecting manufacturing information in real time and ensuring alignment between business planning and shop-floor activities.
The company’s warehouse management system is tightly integrated with both ERP and MES platforms, allowing inventory levels, material movements, and logistics information to be synchronized in real time. This integration improves material traceability and supports efficient production scheduling. At the process level, the facility’s DCS controls critical manufacturing parameters such as temperature, pressure, and flow rates. By linking DCS data with the MES, production instructions are directly connected to real-time equipment performance, creating a seamless flow of information throughout the manufacturing process. According to Chugai, this architecture improves data consistency, traceability, and overall operational reliability while reducing opportunities for human error.
To support this connected environment, Chugai relies on a combination of industry-standard communication protocols and data integration technologies. Business systems exchange information through SAP interfaces, including IDocs and APIs, while equipment-level data is captured using OPC connectivity and the PI System. Process and equipment data collected from the plant control systems are transferred through the PI System and integrated into the MES, enabling a continuous flow of information from manufacturing operations to higher-level business applications. The loosely coupled architecture enables individual systems to be upgraded or expanded without disrupting the broader infrastructure. This approach provides flexibility, scalability, and long-term maintainability as manufacturing requirements evolve.
One of the most significant benefits of the digital strategy is broad access to real-time operational data. Through integration with the PI System and visualization tools such as PI Vision, employees across manufacturing, quality assurance, maintenance, research and development, and management functions can access the same up-to-date information. Chugai refers to this environment as a “single source of truth,” ensuring consistent and reliable data across departments. This transparency supports faster decision-making, stronger collaboration, and more effective problem-solving throughout the organization. At the same time, role-based access controls help maintain data security and governance by restricting information access to authorized personnel.
The company has also developed advanced reporting and dashboard capabilities to enhance daily operations. Equipment and process data are consolidated within the PI System and displayed through customizable PI Vision dashboards that provide real-time monitoring and trend analysis. These dashboards are used extensively for digitized inspections, reducing reliance on paper records while improving the speed and accuracy of plant assessments. Manufacturing and maintenance teams can quickly evaluate equipment performance, identify emerging issues, and make informed operational decisions based on consistent data. Chugai has also established a foundation for remote operations through digital interfaces, surveillance systems, and remote data access capabilities, positioning the facility for future advances in remote monitoring and control.
Beyond improving current operations, Chugai views its digital infrastructure as an investment in future growth. The integrated architecture supports data visibility, continuous improvement initiatives, and advanced manufacturing practices while making future expansions easier to implement. Although the development and deployment of such a comprehensive digital ecosystem required significant planning and investment, the company believes the long-term benefits—including enhanced efficiency, operational agility, and scalability—will continue to deliver value as production requirements evolve.
As pharmaceutical manufacturers increasingly pursue digital transformation, Chugai’s FJ3 facility demonstrates how combining automation with a robust digital infrastructure can create a connected, flexible, and data-driven manufacturing environment. The facility’s Honorable Mention recognition at the 2026 ISPE Facility of the Year Awards reflects the industry’s growing emphasis on integrated digital operations as a cornerstone of manufacturing excellence.
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