Manufacturing Improvements using Lean Manufacturing Tools

Abstract

This project was executed in a Pharmaceutical Company in Guayama PR. The process selected is the manufacturing of a new product produced since July 2008. It is a solid dosage drug or tablets. The manufacturing consists of weighing, blending, compression, coating and visual inspection. It was selected since it was observed high product cycle times, high inventory levels, non uniform manufacturing procedures, poor equipment maintenance and activities that are non value added. The goal is to identify the wastes, which is any activity that does not add value. A value stream map was developed to look for opportunities to eliminate wastes and improve the manufacturing process. In the value stream map, the production flow was analyzed for understand the company's current cycle times, machine equipment capacity, and process communications. In addition, it was collected and analyzed information related to the product from start to finish for mapping purposes. The Takt time was calculated from the collected data. Cycle times, down times, work in process inventory, and material and information flow paths were documented. Based on all the information gathered, the Pharmaceutical Company may implement Lean manufacturing methodology to increase the productivity and the quality of this new product.