Case Studies

Lean Labs for an Indian Pharma Major

Lean Labs for an Indian Pharma Major

Sector Pharmaceutical

Situation

XYZ pharmaceuticals Ltd (name changed to protect confidentiality) is a leading Top Pharmaceutical Company manufacturing total healthcare solutions, active pharmaceutical products.

Actions taken

The project kicked off with the champions training for the leadership team along with 2 days training program in Lean for the project team members followed by an open discussion about the queries related to project.

Results

Defined, structured and controlled laboratory processes delivering more consistent and predicable laboratory performance.

Situation – deep dive

XYZ pharmaceuticals Ltd (name changed to protect confidentiality) is a leading Top Pharmaceutical Company manufacturing total healthcare solutions, active pharmaceutical products. This assignment focused on streamlining their Quality control lab with an aim to improve their key metrics by way of Lean Labs project.

The project objectives therefore were:

  • Increase Sample/Analyst Ratio
  • Reduce the Lead time for samples analysis

Actions Taken – deep dive

SSA followed its proprietary 4D approach to this Lean Lab transformation. In the Diagnose Phase (D1), a team of consultants from SSA led a value stream mapping exercise, which aimed to capture the "current state" end-to-end activities of the lab. The activities were classified based on value classes (VA/NVA/BVA). This exercise also threw light on redundant movements, hidden wastes, load balancing issues, laboratory equipment management, laboratory chemicals management, and housekeeping practices.

In the Design Phase (D2), SSA developed a Future State Value Stream Map and identified several improvement projects (kaizens) that would play a vital role in achieving the objectives. The Deploy (D3) phase involved activities like Layout corrections, Inventory management system, 5S/housekeeping efforts, setup time reduction, and implementation of first-in-first-out (FIFO) systems, among other efforts. In Develop (D4), Dashboards were created for monitoring the Key Performance Indicators to enable the team to sustain the gains.

Results – deep dive

  • Defined, structured and controlled laboratory processes delivering more consistent and predictable laboratory performance
  • Detailed understanding of lab capacity and resourcing requirements
  • Reduced lead-times
  • Improved RFT (Right First Time)
  • Significantly Increased productivity