Our client is a pharmaceutical company, boasting a global presence with more than 10 plants and operations spanning across the world. With a revenue of billions euros, they are a prominent player in the pharmaceutical industry. The project primarily focuses on Oral Solid Blister products.
Business Challenge
Navigating a complex project plan, our client embarked on assesment phase to four different plants within a span of four months. Faced with stringent deadlines, they had to ensure the project progressed smoothly amid the tight schedule.
Moreover, grappling with low data accuracy and availability hindered effective decision-making, exacerbated by resource constraints due to an under-dimensioned OpEx organization. To add to the complexity, the company had to manage an intense onboarding program to keep everyone aligned with the project objectives, further complicating the operational landscape.
Approach
Hands-on approach to carry out activities at two levels:
- Corporate: implementation of management system, design and support the creation of a new OpEx structure, definition of a standard calculation for production yields, creation of a system to monthly monitor unitary cost
- Plant: assessment and deployment of strategic targets declined into six main topics (service level, production, cost, quality, yields, safety)
- Development of effective and reliable performance analysis of as-is and to set targets
Main Results
- 37% cumulative OTIF improvement in one year
- 10% cumulative volumes production in one year
- Decreased cumulative unitary conversion cost by 9% in year 1
- 1% cumulative yields in one year
