Cycle Time Reduction using Lean Manufacturing Techniques for a Solid Pharmaceutical Product

Abstract

Abstract ⎯ The purpose of this project was to demonstrate that the Lean Manufacturing techniques could be applied to a Solid Pharmaceutical Product in order to reduce the cycle time. During the year 2007, the Solid Pharmaceutical Product studied had 52 days of cycle time. The goal is to reduce the cycle time 25% or to 39 days. Lean Manufacturing tools used in this project was the process map to develop the required knowledge of the manufacturing process and the Value Stream Mapping where the values added and non-values added activities were identified. A Multidisciplinary team, essential for creation and implementation of new ideas, a list of improvements was generated and weighted for prioritization. This prioritization matrix is the foundation to start the implementation of improvements. After the Multidisciplinary team implemented the short term improvements in the Manufacturing Area, it was observed that the Product Cycle time decreased to 37 days in the third quarter of the 2008. After completion of the study, it was proved that the Lean Manufacturing techniques can be applied to a Solid Pharmaceutical Product and can radically reduce the cycle time. Key Terms ⎯ Kaizen, Value add (VA), Value Stream Map and Waste (muda).