Project Summaries

Pharmaceutical Manufacturing Site

Lean Program Design and Implementation

 

The Challenge

A large Midwestern pharmaceutical company identified that their current (in-use) traditional operational strategy of processing raw material, manufacturing, and packaging the final product could be done more efficiently and cost less.   Site Leadership benchmarked other pharmaceutical companies employing a lean model and decided to transition the operational practices from a traditional pharmaceutical manufacturing process to a lean model of manufacturing over a one year period.

The Solution

Performance Validation (PV) provided a dedicated Lean Six Sigma Green Belt Consultant to lead in the development of the lean manufacturing model.  The Green Belt provided the following development and implementation to the client:

 

Design Concept:

• In a manufacturing facility, having similar work environments it is critical to reduce cycle time, variation, operational costs, and increase health and safety for the employee.  To achieve this design concept, each manufacturing operation (selected for lean optimization) was evaluated and standardized to capture these benefits.  Areas evaluated included:
  • Tablet Coating Operations
  • Sampling
  • Dispensing
  • Tablet Processing Operations
  • Packaging
  • General Offices
  • Consumables Inventory Space
  • PPE Cabinets
• Implementation:
  • Each functional area selected for lean optimization was decided by the client based on the PV Consultants recommendations.
  • A client champion for each area was identified to work with the PV  consultant. 
  • The PV consultant provided training and mentoring to the client champion
    on the Five S Program which focuses on having visual order, organization, cleanliness, and standardization within the work cells.  This ensured that all of the champions had the knowledge base necessary to complete the lean initiative in each of their respective areas. 
  • PV led and facilitated communication with the cross functional team
    throughout the initiative.
  • PV led the champions in implementing the standardization phase of the project in a consistent manner within each operational area.
• Sustainability:
  • PV developed a post implementation audit program for each functional area to provide for sustainability of the program.

The Results

The Lean Program was successfully implemented on time and within budget throughout the large manufacturing site. 

The Benefits

The establishment of lean manufacturing controls within the manufacturing cells provided the following benefits:

• Increased Health and Safety

• Targeted Point of Use

• Accurate Inventory Process (KanBan)

• Accurate Space and Boundary Controls based on functional needs

• Cycle Time Reduction

• Reduced Variation

• Reduced Complexity

 

Operational Cost Savings: $78K/Year

 

Inventory Cost Savings: $16K/Year

 

For additional information, contact:

 

Daniel Cornpropst

Lean Six Sigma Black Belt

e-mail

866-300-9542

Mobile: 317.519.0984

2601 Fortune Circle, Suite 200C

Indianapolis, IN 46241