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Over the past few years, inspectors in the pharmaceutical industry have begun to recognize the immense advantages of using indoor drones for gathering visual data. These drones, specially designed to navigate tight and confined spaces, have become indispensable tools for inspectors who need to conduct internal inspections.
Indoor drones have proven particularly useful for examining various critical assets within the pharmaceutical sector. Here are some examples of what these drones are used to inspect:
- Storage tanks
- Pipe racks
- Cables
- Conduits
- Pressure vessels
- Other assets requiring regular internal inspections
Traditionally, inspectors would have had to physically enter these assets to conduct inspections. This involved moving systematically through the asset with a flashlight and camera, capturing visual data about the internal conditions. If the asset was large, inspectors might have had to use scaffolding or rope access to reach every part of it.
However, all these methods—entering confined spaces, working at heights on scaffolding, or using ropes—pose significant risks to the safety of inspectors. These activities can result in accidents, injuries, or even fatalities. Indoor drones offer a safer alternative by eliminating the need for inspectors to personally enter hazardous areas. Instead, they can pilot the drone remotely, capturing detailed visuals without putting themselves at risk.
One notable example of cost savings comes from a recent inspection at a major pharmaceutical facility. Inspectors managed to save 60,000 Euros in a single round of inspections by utilizing an indoor drone. This saving was primarily due to drastically reduced downtime. The drone was far more efficient at collecting visual data compared to a human, allowing the tanks to be put back online much faster.
In many cases, companies have reported slashing their inspection costs by up to 90-95% simply by switching to indoor drones. Additionally, these drones eliminate the need for costly scaffolding, which can run into tens or even hundreds of thousands of dollars per inspection. Reducing or eliminating this requirement leads to significant cost savings.
Indoor drones also dramatically decrease turnaround times for inspections by removing the need to construct temporary structures like scaffolding. Setting up and dismantling scaffolding can take several days or even weeks, during which the asset remains offline. In the aforementioned inspection, inspectors at a large pharmaceutical company managed to nearly halve the time required for inspections by using an indoor drone.
Another key advantage of indoor drones is the ability to capture high-quality visual data. The Flyability Elios 2 drone, for instance, offers 4K HD video and high-quality images, along with advanced stabilization and lighting features. This allows pilots to focus on crucial details in the captured imagery, enhancing the quality of the data collected.
Recently, inspectors used the Elios 2 drone during a riboflavin test at a pharmaceutical production plant. They successfully captured high-resolution images showing the cleanliness inside the tanks during a quality control check. Normally, this type of inspection would require an inspector to physically enter the tank and visually assess its interior. However, thanks to the excellent visual data, inspectors could remain outside and review the footage remotely to confirm the absence of riboflavin.
The drone's ability to access tight and confined spaces is another major benefit. Its protective cage design allows it to collide with surfaces and continue flying. This feature enables inspectors to maneuver the drone close to walls and surfaces, providing a clear view to detect any potential defects.
Moreover, indoor drones allow for more frequent inspections. By enabling quick and easy access to hard-to-reach areas like pipe racks or tanks, these drones facilitate regular spot checks. Regular inspections help improve maintenance practices, reducing both planned and unplanned downtimes caused by equipment failures.
Finally, there's the matter of data localization. Flyability's Inspector 3.0 software is tailored for inspection professionals. With this software, inspectors can mark defect locations in their inspection footage. This makes it easier to revisit these points in future inspections or share them with other stakeholders in the maintenance process.
Overall, indoor drones have revolutionized the way inspections are conducted in the pharmaceutical industry. They enhance safety, reduce costs, save time, provide high-quality data, and increase the frequency of inspections. These advancements are paving the way for smarter and more efficient maintenance practices in the field.