Case Studies

Lean in Pharmaceutical Industry

Lean in Pharmaceutical Industry

Sector Pharmaceutical

Situation

This project focused on application of lean methods in a pharmaceutical industry. The aim was to identify and eliminate non-value adding “waste” across the entire manufacturing value stream.

Actions taken

SSA undertook a complete end-to-end study of the value stream with an aim to unearth entrenched processes and practices that contributed to “waste” leading to need to additional manpower and wasteful usage of resources.

Results

Around 10-15% manpower were found surplus as a result of this exercise. The study also helped to unearth opportunities for saving material, time and cost.

Situation – deep dive

This project focused on application of lean methods across a pharmaceutical industry. The aim was to study and unearth “waste” in the system that added to the burden of excessive efforts and resources. This project involved deep-dive time & motion studies, method studies and recommendations for improvement.

Actions Taken – deep dive

  • Deep-dive time and motion study
  • Identifying all forms of non-value adding waste
  • Work simplification and improvement opportunities
  • Solution roll-out and sustenance

Actions Taken – deep dive

Actions Taken – deep dive

Results – deep dive

  • Nearly 10% reduction in manpower
  • Avoidance of wasteful overtime and subcontracting
  • Improvement in work practices to reduce burden to operators