Case Study 2-05438
Without data, it’s just an opinion
A pharmaceutical company requested IET’s support to develop accurate production
standards for a key manufacturing area because important decisions about the
area’s future had to be made. Based on the standards IET developed, managers
eliminated one entire shift in response to changing volumes.
A world-class developer and manufacturer of prescription and over-the-counter
Production scheduling. Manpower allocation. Budgeting All of these business
functions were consuming more time because the manufacturing operation had to
rely on standards that were several years old. These standards did not reflect the
product and process changes that had taken place over the years. Valuable
managerial resources were being expended to adjust and modify the results of
business systems that used inaccurate data. Important decisions were being made
with less-than-best information.
An IET engineer immersed himself in the facility’s sterile manufacturing operations.
Before conducting any time studies, it was essential to understand the process
intricacies and establish rapport with the operators. IET developed an intimate
understanding of each process step from preparation through batch manufacturing
to packaging before conducting stop watch time studies. By noting and recording
times for detailed work element steps, non-essential activities and interruptions
were excluded from the results. In addition, this technique allowed engineers to
estimate accurately the effect of future process or method changes on the product
Approximately 200 products were updated with engineered standards. Armed with
new, accurate standards, manufacturing managers decided with confidence that
one production shift could be eliminated.
© 2015 IET, Inc. Measure · Simplify · Standardize · Realize