A root cause analysis of stock-outs in the pharmaceutical industry

Abstract

PharCo (an assumed name) is a leading global healthcare company with well-recognized brands of both pharmaceutical and consumer healthcare products. As PharCo continues to expand its global presence, product stock-outs in their pharmaceutical business unit have been consistently increasing. PharCo suspected that manufacturing quality defects were a major cause of stock-outs, reducing the production yield and preventing the company from meeting customer demand. To help test this hypothesis and address the stock-out challenge, we reviewed existing research on the subject of product stock-outs within the pharmaceutical industry. To understand PharCo's manufacturing process, we conducted on-site visits and reviewed their quality control practices. Finally, we designed a mixed methods approach that combines qualitative and quantitative techniques to analyze the root causes of product stock-outs at PharCo. The analysis revealed that, instead of manufacturing quality defects, regulatory issues were the primary cause for stock-outs at PharCo. Regulatory challenges associated with developments such as new product launches, license renewals, and formulation modifications need to be addressed for PharCo to reduce their stock-out level.