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Pharmaceutical Industry: Reliability Improvement & Equipment Set-up Optimization

Capability

Operational Improvement

Client

A major generic pharmaceutical company

Problem

Frequent and long delays in cleaning, setting-up and running dry dosage (tablet press) equipment adversely impacted the client’s overall production schedule, staffing/overtime levels, and were sometimes linked to operations or quality problems that affected waste/yield.

Approach

 A two pronged approach to improving the process was utilized. First, a system for tracking, analyzing and correcting root causes for delays was established. The team identified/quantified major technical issues, frequent equipment failures, and major systems issues (i.e. planning and scheduling) that caused process delays, and led a multi-function plant reliability team to address these issues. Then, using tools such as detailed process mapping, video taping and analysis, and focus interviews, a set-up optimization team was formed and facilitated by Tunnell to establish and standardize processes for setting up each type of tablet press. 

Results

 Outcomes of this project included:

• Reduced number and frequency of delays in dry dosage
• Established a system of standardized equipment, procedures, and work practices for each type of tablet press that resulted in a 25%-33% reduction in set-up times and eliminated major delays in the set-up process
• Trained set-up mechanics, cleaning crews and operators in the new standards and procedures. Mechanics and operators were “thrilled” with the new and simplified processes
• Developed detailed inventory of ancillary and test equipment and helped Operations assure that it had the proper amount of functioning equipment to eliminate delays due to missing or broken equipment
• Established preliminary set-up guidelines (documented by product) to provide starting points for tablet press operating conditions to minimize the time to achieve desired product characteristics at start-up
• Made detailed videos of set-ups to be used for developing improved training program for set-up mechanics and operators

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