Real Lean Transformation

Multi Product and Multi Presentation

Client Environment

Multi Product Tablets, Sprays and Gels

 

Geography

Single site project in Northern Europe

 

Objectives

The primary objective of this project was to significantly improve batch release lead-times and consistency. Ancillary objectives included the optimization and right sizing of the QC organization structure and rationalization of Lab shift patterns

 

Solutions Deployed

  • Design and Implementation of Levelling, Flow and Standard Work solutions for each significant lab work stream

  • Implementation of effective Short Interval Control and Performance Management processes

  • Design and implementation of a digital visual management solution

  • QC Organization re-design and implementation

Results

  • 46%Reduction in average lead-times

  • Increase in the % of batches released on-time from 37% to 91%

  • Absorbed an 11% increase in batch volumes with zero increase in Lab resources