Manufacturing Lean Six Sigma case study

- Customer satisfaction
- Teamwork
- Streamlined processes
- Reduced costs
1. Pharmaceutical manufacture: OOS and the value of a gemba walk
1. Pharmaceutical manufacture: OOS and the value of a gemba walk
Client Sector:
Life Sciences manufacturing
Summary Results:
  • Cpk improved dramatically from the generic 0.35, to 1.16 and 1.17
  • The reject rate fell from 18% to 1%
  • The cost savings on the reduction in investigations was considerable
  • The client’s reputation was restored in the market
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4. Raw material sampling: pharmaceutical manufacture
4. Raw material sampling: pharmaceutical manufacture
Client Sector:
Life Sciences manufacturing
Summary Results:
  • The revised process flow had 18% fewer steps
  • The error rate reduced by 91%
  • The average sampling time reduced by 45%
  • The resources required reduced from 3 to 4 people to 2 to 3 people, depending on the sampling procedure

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10. Digitization/ automation of key performance indicators in manufacturing
10. Digitization/ automation of key performance indicators in manufacturing
Client Sector:
Life Sciences manufacturing
Summary Results:
  • Automated online SPC implemented – linking machine, databases and operations management
  • Live real-time online graphics on display on the production line
  • PowerBI software and dashboard now managed by the client
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