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Context

A major pharmaceutical company had launched a global program to streamline its efficiency "more with less"

 

Objectives

  • The key objective was to increase productivity in the visual inspection department. The key metric was the number of doses inspected per FTE
     
  • Challenge: "45% AVI volume increase in 2016 would require xxx new FTEs w/o productivity gains; however this creates a gap of xxx FTEs with Dec 2016 budget"

 

Our Approach

  • Conducted diagnostic to identify levers and estimate potential savings:
    • Organization of workshop to identify potential levers and align with experts on what analysis to be conducted to estimate the size of potential gains
    • Conducted 1-to-1 interviews with cross-functional teams (eg. Production, quality, logistics, maintenance, etc...) to estimate effort and timings for implementation
    • Identification of 14 levers and prioritization in terms of impact vs effort/timing
    • Identification of 7 levers selected for implementation
       
  • Implemented 7 prioritized levers
     
  • Estimate gains (levers) performed while taking into account interdependencies between different levers

 

Results

  • Resulted in productivity gains of 27%
     
  • Department maintained the same levels of production with a reduction of 38 FTEs 
     
  • Recurrent annual cost saving of € 2.8M
     
  • Therefore the department will be capable of handling higher volumes with fewer FTEs