In pharma manufacturing, demand cannot outstrip supply. So, when the production site of a European pharma company noticed safety stocks declining at an alarming rate, they knew they had to act fast.
The production site of a European pharmaceutical company was in a fix. Safety stocks of drugs were declining faster than production could manufacture them. Urgent measures were required to avoid undersupply.
A combination of outdated equipment, unstable processes, and talent losses had created a perfect storm:
We knew our team had to move fast.
We implemented a focused Production Efficiency Program (PEP) based on Lean principles to:
And to deliver real-time production efficiency information, we equipped critical machines with IoT tracking devices.
Throughput increased by >30% without spending capital. Stock-outs and backlog were cleared to zero. On top of that, process deviations were reduced by 25%, and lead times of 140 days were cut in half. To build on this momentum key personnel were trained to sustain the production efficiency program and help guide the site one step closer to a Pharma Manufacturing Excellence rating.
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