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PHARMACEUTICAL INDUSTRY :
Reliability Improvement & Equipment Set-up Optimization |
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| | Client: |
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A major generic pharmaceutical company
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| | 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.
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| | 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 & 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.
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| | Results:
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Outcomes of this project included:
Reduced number & 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 & 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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