Real Lean Transformation

Pharmaceutical Packaging Operation

Client Environment

Pharmaceutical Packing Operation with large volume of finished goods SKU’



European site, serving international customer base



  • Improve delivery performance (OTIF) to customer base

  • Optimise capacity & productivity in the packing operation

  • Provide improved visibility of upcoming workload for support functions such as QC & QA

  • Re-engineer the planning process


Solutions Deployed

  • A ‘Rhythm Wheel’ based scheduling process for packaging operations

  • Re-designed planning processes - via RACI, SIPOC, flowcharts, meeting agenda’s & Planner Standard Work

  • Clearly defined lead time targets & KPI’s for all relevant functions


  • Increased packing capacity & productivity of 10% - 20%, via a reduction in line clearance frequency & complexity

  • Improved delivery performance (OTIF) of ~30%

  • Standardised planning process for scheduling of packing operations

  • Improved visibility of upcoming workload