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Finnish pharmaceutical manufacturer
Redesign of the production facility using Lean methods
Background:
The global demand for products is increasing, and the client company has grown its market share organically.
Problem:
The current capacity of the factory will not be sufficient to meet demand in the coming years. The current structure and operating models of the factory may not be able to comply with the increasingly strict regulations in the pharmaceutical industry in the coming years. The ergonomics of some production phases are challenging, and the work is physically demanding.
Goal:
The factory's capacity is to be doubled. Compliance with future regulatory requirements is to be ensured for the next 10-15 years. The entire staff is to be involved in the planning, and a concept for the factory is to be developed in which, in addition to achieving the goals, the entire staff is committed and where it is good to work.
Implementation:
Value stream descriptions of processes
Building and piloting the mock-up
Factory layout one space at a time
Result:
The production capacity approximately doubled with the same staff in the new facilities.
Architectural planning costs were hundreds of thousands of euros below budget thanks to the preliminary design.
With participation, the entire staff committed to new factory solutions, and job satisfaction improved significantly.
Internal logistics costs decreased by about 50%.
