Client:A leading pharmaceutical manufacturing company produced small & large volume parenteral ranging from 100ml to 1000ml. Business volume from this unit is Rs 95 cr. It’s a continuous manufacturing company involving Solution preparation, Bottle filling station, Sterilization, testing & Packing.
Duration: 2 years of engagement
Problems
Lower capacity utilization as 78%. High overall rejection level which is at 1.6% & Bottle filling yield at 95 %. Frequent machine breakdowns, high internal complaints on quality, high turnaround time to resolve the customer compliance management.
Action:
Holistic continual improvement culture building program involving unit owner to the last connected worker in the facility.
Transformation of 15-year-old traditionally managed unit, Building confidence & positivity in participating team members. Significant gains in objectives of improvement projects in Production capacity, Delivery, Quality, Cost, Motivation.
Improve skill levels & performance in above areas.
We applied the focused improvement approach to create a mindset for implementation with cross functional team members for learning & implementation.
Program started with educating senior management staff, managerial & operational people, for conceptual training, problem-solving skills, aligning with core issues. Started disciplined data based, facts finding, Gemba based analysis & improvement
Further strengthened the processes by eliminating all types wastes. Significant change came when top management started attending daily Visual board meeting on shop floor with every team member & quick issue resolution through steering committee. Offline Coaching to team on plan of action implementation & handholding for solving practical difficulties, helped team to improve their performance.
Results
- Empowered motivated staff & workforce
- Bottle Filling Line Capacity utilization improved from 78% to 90+%
- Bottle filling yield improved from 95% to 98 %
- Rework / Rejection/ reduced by 50+%
- Compliance management turnaround time reduced from avg 180 to 45 days
