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PHARMACEUTICAL INDUSTRY :
Manufacturing Performance |
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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: | |
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: | |
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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