FEA technique implementation analysis in pharmaceutical packaging development

Abstract: Background & Problems formulation: Johnson and Johnson (JnJ) is a world-famous pharmaceutical manufacturing company. The packaging team of JnJ spent too much time and money on current laboratory transportation testing, which is at the ending stage of the packaging development process. Currently, JnJ is doing its packaging transportation test fully in a laboratory, which means that they need to produce the whole prototype (prototype of product, primary, secondary and tertiary packaging). Acquiring a prototype means big efforts in terms of ordering from suppliers, ordering from other JnJ production lines, etc. In many transportation test cases, JnJ needs to order a big quantity of packaging elements like paper cartons or blisters (since suppliers do not provide small quantities). Such a process might bring problems like waste (ordering an unnecessary amount from supplier) and long lead time (order from supplier, sending to lab, etc.). As a digital simulation tool, the FEA technique is capable of simulating different forces, impacts and temperature, which shares some similarities with JnJ packaging testing in transportation. These two features of FEA seem to fit JnJ needs and requirements as they are exploring alternatives to replace packaging transportation testing in the lab. Potentially, FEA could help JnJ to digitize its packaging testing process. Research purpose: The purpose of this research is to investigate how FEA could affect the packaging development process, furthermore to understand how to implement FEA in the packaging development process. Methodology: The research is identified as exploratory research. First the literature review about the packaging development process and FEA capabilities are done. Then a single-case study is carried out. The authors held interviews with people from the JnJ packaging team to have a better understanding of the packaging development process and their views of FEA implementation. Other interviews are done with FEA service providers to know FEA capabilities in reality. A questionnaire was then conducted to identify potential benefits, success factors, and barriers for JnJ to implement FEA. An analysis including literature review and empirical data was done in the end.