Output Increase and Meeting Delivery Targets: API Manufacturing
Capacity of high-urgency API increased by 45% in only 19 weeks. Cycle time improvements of another product enabled the agreed customer delivery date to be met.
Pharmaceuticals – API Manufacturing
19 weeks - 2 consultants
- Reduce cycle time of bottleneck process step by 6 hours for high-urgency Drug A.
- Bring delivery of Drug B forwards to on or before the agreed customer delivery date by saving 4 weeks in production schedule.
- Cycle time for Drug A bottleneck process reduced by >10 hours in 19 weeks
- Drug A weekly output increased by 45% vs pre-project baseline
- All Drug B delivery deadlines met
Why was Chartwell brought on board?
Improvement was needed to meet increased demand for Drug A and to avoid late delivery on Drug B. Achieving the project objectives was worth almost $3m. This pilot project demonstrated the scale of improvement possible by focusing on two high urgency products.
Core Project Workstreams
Increasing output of Drug A: Reducing bottleneck cycle time by 15%
- Chartwell consultants and client team members used a structured methodology to reduce the bottleneck cycle time.
- Powerful opportunities to conduct sub-processes in parallel or shorten process step times were identified.
- These changes challenged deeply ingrained constraints such as the times at which quality samples were taken.
- Rigorous trials proved that breaking constraints was not contradictory with meeting best-practice specifications.
Meeting the delivery deadline for Drug B: Reducing Changeover time by 32%
- During the Opportunity Scan, Changeover duration was highlighted as a significant lever for achieving the project goal.
- Planning tools made following improved Changeover protocols easy and repeatable for operators and tracked their progress against these new standards.
- Process experts and Chartwell consultants worked together to define Drug B's critical path.
- Targeted reductions to the cycle times of steps on the critical path slashed overall batch processing time.
Training the Site Team in "Improvement Cycle Methodology"
- Nearly 50 staff were trained in our fundamental methodology to set them up for success after the project end.
- Handing over the tools and structures that underpin Chartwell's approach ensured achieved results were truly sustainable.