25% Efficiency Gain & 1.5x Faster BOM Integration with AI-Powered Power Apps

Overview

The client is a $20 billion global pharmaceutical leader specializing in the development and distribution of active pharmaceutical ingredients (APIs), excipients, and consumables critical to drug manufacturing. Despite their scale and strong industry reputation, their materials integration processes were fragmented, inefficient, and heavily dependent on manual effort. Data resided in isolated systems, while Excel-based tracking and cleaning processes contributed to frequent human errors and operational delays. These inefficiencies consistently disrupted manufacturing timelines, which in turn affected downstream drug production and delivery to market.

Recognizing the impact on both operational performance and regulatory compliance, the client’s leadership team prioritized a transformation of their materials integration process. Their goal was to improve efficiency, minimize errors, and enable more strategic decision-making across procurement, supply chain, and production functions.

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Challenges

The client’s existing processes lacked the agility and visibility required for a modern, global pharmaceutical operation. Key challenges included:

‍Visibility Gaps: Without a centralized dashboard, material tracking and status monitoring were conducted manually. This led to poor visibility into process bottlenecks and frequent missed deadlines. Teams lacked confidence in the accuracy of available data, and leadership struggled to make proactive decisions due to outdated or incomplete information.

Process Bottlenecks: Material integration relied on disconnected spreadsheets and labor-intensive workflows. Approval processes were slow, inconsistent, and prone to errors, causing delays in integrating new item codes into the Bill of Materials (BOM). This inefficiency was compounded across global manufacturing sites, creating inconsistent performance outcomes.

Data Quality Issues: Data sources were fragmented, inconsistent, and required significant manual cleaning. The absence of standardized processes for data ingestion and validation led to frequent rework, duplication, and conflicting records across systems, undermining the accuracy of reporting and analysis.

Timeline Delays: End-to-end material integration cycles often extended up to seven weeks, severely limiting agility in production planning and responsiveness to market demands. This had a direct impact on operational costs, customer satisfaction, and regulatory timelines.

Value Delivered

SOLUTION

Aligned Automation partnered with the client to reimagine their materials integration framework through a targeted AI-powered solution built on Power Apps. The transformation focused on optimizing data, automating workflows, and ensuring scalability, while preserving the integrity of existing business processes.

Key components of the solution included:

Workflow Automation: Developed a New Item Code (NIC) Tracker within Power Apps to streamline the creation, approval, and integration of new codes into the BOM. This tracker established transparent, auditable workflows with clearly defined ownership and accountability.

Real-Time Visibility Platform: Established interactive dashboards that provided real-time insights into material integration progress. These dashboards highlighted delays and bottlenecks across approvals, requests, and material readiness, empowering teams with actionable data to drive faster decisions.

Data Quality Optimization: Consolidated siloed data sources into a unified data model, eliminating duplicates and cleaning datasets through AI-powered validation. This ensured that Power Apps was consistently fed with reliable, accurate, and standardized data, which reduced the need for manual intervention.

Intelligent Integration: Deployed AI-driven agents to detect anomalies in incoming data streams, flag inconsistencies, and provide predictive insights to support proactive materials management. This helped teams anticipate and resolve potential delays before they could escalate.

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CONCLUSION

This transformation went beyond implementing technology. It redefined how materials data flows through the business to improve efficiency, accuracy, and agility. Aligned Automation worked closely with the client to align technology with operational realities and ensured seamless adoption that delivered immediate value.

Through AI, data optimization, and Power Apps, the client unlocked measurable performance improvements and established a scalable foundation for future innovation. This project illustrates how operational excellence and AI-driven insights can solve longstanding challenges and support long-term business growth.

Capabilities

User Interface (UI) Design

Data Optimization

Data Integration

Agentic AI Implementation

About Client

The client is a $20 billion global pharmaceutical leader with a diverse portfolio spanning the development, manufacturing, and distribution of active pharmaceutical ingredients (APIs), excipients, and consumables that are essential to drug formulation and production. Serving a broad base of pharmaceutical and biotechnology companies worldwide, they play a critical role in ensuring the availability of high-quality, compliant raw materials that enable life-saving and life-enhancing therapies to reach the market. Their scale, global reach, and deep expertise have positioned them as a trusted partner to some of the world’s most prominent drug manufacturers.

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25% Efficiency Gain and 1.5x Faster BOM Integration through Strategic Data Optimization and AI-Powered Migration from Excel to Power Apps

Challenges

The Approach

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