Kaizen Institute - Success Story
Pharmaceutical
Flow Management
Client Profile
India's premier biopharmaceutical company develops, manufactures and supplies generic active pharmaceuticals.
Improvement Potential
Unbalanced packing line: Allocation of work is not balanced in the packing line which results in lost of production time, rejects and productivity loss.
Project
- Productivity improvement in the manual packing line.
Our Approach
- Balancing the packing line
- Re-arrangement of manpower
- Implementation of a Mizusumashi system
- Rejection analysis for reducing rejects
Key Results
- Productivity/Manpower for Vial packing increased by 31,6 %
- Productivity/Manpower for Pick-fill and Seal machine packing increased by 92%
- Rejection level for the last 30 batches reduced by 85 rejections
- 5S Audit score increased from 30% to 56%
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