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Pharmaceutical
Industry:
Manufacturing Performance / Process
Capability and Control
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Client: |
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A multi-billion
dollar pharmaceutical company with multiple sites across the U.S.
and Puerto Rico.
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Problem: |
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Need to increase
manufacturing capacity. Need to reduce variation, cycle time and waste
in performance of key manufacturing processes. Not a lot of time to
meet the organization’s financial goals.
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Approach: |
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Developed baseline
measurements on key manufacturing processes. Assessed the process
control characteristics of key processes. Assessed level of process
capability (for those processes in-control). Determined ROI for projects.
Trained problem-solving teams and team leaders in each of the key
process areas in team process, statistical process control and a structured
problem solving process. Trained and coached management and supervisory
personnel in managing processes achieving quantum improvements in
operating performance in a short period of time. Drove the problem-solving,
waste-reduction process in an accelerated fashion through focused
on-site consultant support of teams and management.
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Results:
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Increased manufacturing
capacity 40% (12 months) eliminating the need to invest $12 million
in new facilities. Increased packaging line production +75% and operations
production +125% through improved on-line metrics, continuous bottleneck
awareness, and timely line balancing. Pharmacy Warehouse: Better space
utilization (10%) through improved material flow and a 50% reduction
in “internal customer (manufacturing)” material delays. Other Manufacturing:
Drying cycle times down 50%, laser drill up 20%, coating up 40% production,
tableting up 30% production. The total bottom line savings for the
project were approximately $22 million.
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