Reducing Lead Times for a Large Generic Drug Manufacturer

Reducing Lead Times for a Large Generic Drug Manufacturer

The Challenge

  •  Corporate level initiative of a large generics manufacturer to increase productivity and reduce manufacturing lead time at its key sites
  •  Each site manufactures a large number of products and constantly faces tradeoffs between minimizing changeovers and maximizing flexibility to market demands

Tefen Delivered

  •  OEE improvement of critical bottleneck operations by more than 25%
  •  Changeover reduction using SMED techniques
  •  Redesigned planning and scheduling processes to optimize lot sequencing
  •  Redesigned IT tools for productivity tracking, scheduling, capacity, and staffing planning
  •  Deviations and document error reduction
  •  Implementation of Key Performance Indicators to increase visibility

 

Before and After

Results

Benefits from each site varied between $2 - $5 million generated from:

  •  40-60% Lead-Time and WIP
  •  20-40% Reduction in Backorders
  •  15-30% Increase in Capacity
  •  20-40% Reduction in storage space

Shift productivity trend

 

For further information on SMED - click here.