Application of Lean tools to quickly improve the performance of one leader in pharmaceutical industry, in order to deliver timely orders from emerging markets 

Approach

  • A support and operational coaching program, action oriented

  • Focus on the main performance levers: changeover time reduction, cleaning, validation and restarting of production lines

  • Change of scheduling in order to better exploit the capacity constraint 

  • Improvement of availability and reliability of critical equipment by adapting maintenance policies

 

 

Photo de P. Marris dans une usine pharmaceutique

Results

  • Production increase from 470.000 to 809.000 units/week within a 5-week span, then within a 11-week span from the start of the assignment, production has been stabilized to an average 793.000 units/week

  • Changeover time reduction: first of more than 3 hours by the reduction of the frequent overruns, compliance achieved with standard times, then an additional 3-hour reduction compared to initial standard times  

  • The workshop with the worst reputation of the site changed to "exemplary" status. It is frequently cited as a benchmark and was the subject of a report in the internal newsletter

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About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean & ToC training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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Tour Maine Montparnasse, 27éme étage
33, avenue du Maine - 75755 PARIS cedex 15

Tel. : +33 (0)1 71 19 90 40

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