IMPROVE / EXECUTION

Product Selection For Improvement

• Analysis of Lead Time Done by Pareto and Histogram as per below:

T1 Top Quadrant
T2 (more Bxs, High Lead time)
XYZ
Avg. Lead Time

ABC DPM
T3

Plant
No of Bx.
• As per Histogram total 33 Bx. SKU have a Lead time greater than 21 Days (From Jul –Oct).
• After Analyzing by Scatter Chart High No of Bx. & High Lead Time Products are listed bel
Product No of Batches Average Lead Time
ABC 12 28.6
XYZ 12 25.2
DPM 37 22.2
• Amongst that Major 02 Product ABC & XYZ has a higher lead time (Average 28.6 &
25.2 Days Respectively) and total 24 Bx.
• This 03 Product contributing More than 90% of the total Volume Generated from this
Facility.
• Further Stage Wise analysis has to be done for Area of Improvement.
ABC & XYZ - Analysis
• Further Stage Wise analysis Done For the Major Product ABC and XYZ

ABC VA = 7 Days, NVA = 6 days

Total Disp.-RFP Time = 13 days
Scope For So PCE= VA/Total Time = 53.8%
Improvemen
t Here, VA/NVA Ratio is very low which Represents the
Waiting Time or Inventory Time between stages is high for
that we can suggest Improvement ideas.
RFP-Packing Waiting Time: 6 Days
Packing – QA Rel. Time: 9 Days

XYZ VA = 7 Days, NVA = 4 days

Only 4 Bx. Data in

Total Disp.-RFP Time = 11 days

compression

So PCE= VA/Total Time = 63.6%

Scope For
Improveme Here, VA/NVA Ratio is high as compared to other product.
nt
Still inspection Process Time is High So we can work out for
the same.
RFP-Packing Waiting Time: 8 Days
Packing – QA Rel. Time: 16 Days

VA = 5.6 Days, NVA = 7.7 days

DPM Total Disp.-RFP Time = 13.2 days
Scope For So PCE= VA/Total Time = 42.4%
Improvemen
t Here, VA/NVA Ratio is very low which Represents the
Waiting Time or Inventory Time between stages is high for
that we can suggest Improvement ideas.

RFP-Packing Waiting Time: 5 Days

Packing – QA Rel. Time: 4 Days
VA = Process Time, NVA = Waiting
Product Selection For Improvement

• As in Tab-X area the only Product is ZBD 50 mg & PBT 100 mg So Product Selection is
not required.
• Further Stage Wise analysis done for the both Product.

• Here by Stage wise analysis we can see that Disp.-RFI time for Mesalamine
ZBD Product is
Very high (Average 27 Days). Also there is higher time for BSR-QA Rel.
• Stage wise analysis for the product has to be done for better Clarity.
Stage Wise analysis for ZBD Product

ZBD

VA = 15.3 Days RFP-Packing Waiting Time: 3.6 Days

NVA = 9.2 days Packing – QA Rel. Time: 7.6 Days
Total Disp.-RFP Time = 24.6 days

So PCE= VA/Total Time = 62.2%

• Here, PCE is high as compared to other product so we need to reduce process time
also.
• Waiting Time Between Stage is high for Roll Compaction to Granulation.
VA = Process Time, NVA = Waiting
Stage Wise analysis for ZBD Product

ZBD

WT For
QC
Release

Dependency
on third
Party

VA = 11.6 Days RFP-Packing Waiting Time: 5 Days

NVA = 19.8 days Packing – QA Rel. Time: 3.5 Days
Total Disp.-RFP Time = 31.5 days

So PCE= VA/Total Time = 36.8%

• Here, PCE is low because of waiting time between stage is high specially for roll
compaction to Granulation & Coating to Imprinting.
VA = Process Time, NVA = Waiting
QC Sample Release Time analysis
FP Sample Release Time analysis

56% of batches (265 out of 474) are above the stipulated SLA of 7 days 75% of batches (356 out of 474) are above the stipulated SLA of 2 days
Process Time Reduction:

• Process Time can reduce by Following aspects:

• Reduce/Skip testing
• Capacity Improvement.
• SMED to reduce Changeover Time.
• Replacing Old Machine With new machine having better efficiency.
• Based on Summary of Analyze Phase there should be Some Improvement ideas need to
be indentified.
• Kaizens identified as a quick Wins or Future Plans which are listed for Different Stage
wise As per below:
Process Time Reduction:

• Kaizens Identified at stage 1 & stage 2 is listed as per below:

Kaizen at granulation and blending stage
Sr No Area problem Action Status
completed in
1
As per discussion december
2
A As per discussion Completed
3
As per discussion Completed
1
4 As per discussion Completed

5 B

As per discussion completed

completed me person
6 C
reviewer qualification
As per discussion is completed
7 D
As per discussion completed
8 E
As per discussion completed

9 2 F
As per discussion completed
10 G
As per discussion completed
11 H
As per discussion completed
12 Ij As per discussion from March

13 J
As per discussion cpending
14 K
As per discussion Pending
3
15 L
As per discussion Pending