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Applying lean six sigma methodology to a pharmaceutical manufacturing facility: A case study

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dc.contributor.author Byrne, Brian
dc.contributor.author McDermott, Olivia
dc.contributor.author Noonan, John
dc.date.accessioned 2021-03-25T09:04:29Z
dc.date.available 2021-03-25T09:04:29Z
dc.date.issued 2021
dc.identifier.uri http://hdl.handle.net/10344/9918
dc.description peer-reviewed en_US
dc.description.abstract This research examines a case study on the implementation of an effective approach to advanced Lean Six Sigma problem-solving within a pharmaceutical manufacturing site which manufactures acetaminophen (paracetamol containing pain relief) tablets. Though this study was completed in a single manufacturing company, the implementation of this study delivers important application and results that can be deployed in other such manufacturing companies. The manufacturing site faced backlogs in customer orders due to increased demand. Increased demand is due to brand popularity and recognition, product efficacy and a COVID 19 pandemic that intensified the demand for pain relief tablets in an already very busy site. With increased demand, to ensure timely deliveries, customer satisfaction and minimize delays, sources of site productivity losses and wastes needed to be analyzed and reduced or eliminated. Manufacturing Packaging line downtime was identified as one area of concern. The goal of the research was to introduce a problem-solving technique to reduce downtime within a manufacturing site without affecting the production required to fulfil customer demand while increasing product quality. The research utilized an integrated LSS methodology which identifies, stratifies and effectively eliminates non-value adding (waste) activities, by following a 7-step customized problem-solving methodology which resulted in complete elimination of the issue under investigation and savings of just under half a million dollars. The learnings are being deployed and leveraged worldwide across the pharmaceutical organizations parent site and sister sites. The presented results demonstrated that Lean Six Sigma methodology and tools are effective for accurate root causing of problems and enablers of implementation of continuous improvement. en_US
dc.language.iso eng en_US
dc.publisher MDPI en_US
dc.relation.ispartofseries Processes;9, 550
dc.subject Lean en_US
dc.subject Six Sigma en_US
dc.subject Lean Six Sigma en_US
dc.title Applying lean six sigma methodology to a pharmaceutical manufacturing facility: A case study en_US
dc.type info:eu-repo/semantics/article en_US
dc.type.supercollection all_ul_research en_US
dc.type.supercollection ul_published_reviewed en_US
dc.identifier.doi 10.3390/pr9030550
dc.rights.accessrights info:eu-repo/semantics/openAccess en_US


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