India Greenfield Site
Challenge: Global pharmaceutical company with an API formulation and packaging site in Puerto Rico was looking to reduce operating costs by 10% per annum for a three-year period. They were also investigating developing capabilities to manage new, complex products. The client also recognized the need to develop organizational capabilities with respect to lean manufacturing.
Audere Partners worked side-by-side with management to revamp the start-up program midstream to establish a new schedule with clear milestones and accountabilities We implemented an effective organization structure and management operating system integrated across the operation, that would build a culture with behaviors to achieve safety, cost and productivity targets The deliverables of the project were:
Creating a safety focused culture
Install an organizational structure to manage plant commissioning and customer product trials
Design and implement an organizational structure with clear accountabilities and responsibilities to run ongoing operations
Shop floor coaching and engagement through structured and frequent Gemba Walks
Lean and six sigma tools including: Visual management, cycle time improvement techniques, pare to analysis and root cause analysis
Formalized key processes with RACIs
Short interval control, production loss accounting
Management system including planning and performance review meetings and KPIs
Results of our engagement include:
The commissioning and ramp up schedule met its revised deadline for our project with no safety related incidents.
The plant established new greenfield site benchmarks for productivity, quality and on-time shipments.
“The new management system allows us to get to root cause and control non-conformance issues quickly… if we didn’t have these tools we would take much longer to achieve resolution”