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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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