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Operational Excellence in Practice : the Application of a Takt-Time Analysis in Pharmaceutical Manufacturing
Journal
Journal of Pharmaceutical Innovation
ISSN
1872-5120
ISSN-Digital
1939-8042
Type
journal article
Date Issued
2015-06
Author(s)
Abstract
Introduction
Due to increasing cost pressures and structural changes in the pharmaceutical industry in recent years, pharmaceutical manufacturers have been forced to focus on the optimization of their production processes. Therefore, operational excellence is receiving broader attention throughout the pharmaceutical industry. However, too many of these practices are attempting to reduce the cycle time or increase the output of single-process steps rather than optimizing the overall process from a holistic perspective.
Objective
This paper addresses the concept of a "Takt-time" analysis for pharmaceutical manufacturing. A Takt-time diagram is a tool to identify bottlenecks in a production process. It visualizes the cycle time of a product and the times per process step and relates it to customer demand (Takt time). Thus, the bottlenecks in the production flow are revealed, and production can be reorganized. However, the application of the Takt-time analysis to pharmaceutical manufacturers shows specific challenges because of their manufacturing characteristics, such as batch processing.
Methods
The concept for a Takt-time analysis was developed while working on a project with a CMO of an imaging agent to address the practical challenges in implementing its concept in pharmaceutical manufacturing.
Results
The concept creates the basis for a process redesign at a multiproduct production site. It lays the foundation that customer demands can be matched with an aligned production process, and that a seamless production flow driven by customer demands can be realized.
Due to increasing cost pressures and structural changes in the pharmaceutical industry in recent years, pharmaceutical manufacturers have been forced to focus on the optimization of their production processes. Therefore, operational excellence is receiving broader attention throughout the pharmaceutical industry. However, too many of these practices are attempting to reduce the cycle time or increase the output of single-process steps rather than optimizing the overall process from a holistic perspective.
Objective
This paper addresses the concept of a "Takt-time" analysis for pharmaceutical manufacturing. A Takt-time diagram is a tool to identify bottlenecks in a production process. It visualizes the cycle time of a product and the times per process step and relates it to customer demand (Takt time). Thus, the bottlenecks in the production flow are revealed, and production can be reorganized. However, the application of the Takt-time analysis to pharmaceutical manufacturers shows specific challenges because of their manufacturing characteristics, such as batch processing.
Methods
The concept for a Takt-time analysis was developed while working on a project with a CMO of an imaging agent to address the practical challenges in implementing its concept in pharmaceutical manufacturing.
Results
The concept creates the basis for a process redesign at a multiproduct production site. It lays the foundation that customer demands can be matched with an aligned production process, and that a seamless production flow driven by customer demands can be realized.
Language
English
Keywords
Takt time
Pull production
Lean production
Pharmaceutical industry
Cycle time
HSG Classification
contribution to scientific community
Refereed
Yes
Publisher
Springer
Publisher place
New York, NY
Volume
10
Number
2
Start page
99
End page
108
Pages
10
Subject(s)
Division(s)
Eprints ID
245929