Streamline the Value Stream Processes to deliver Growth Capacity


Key Business Challenges and Project Objectives:

Our client manufactures a wide range of veterinary pharmaceutical products. These products are sold in over forty countries worldwide under our client’s brand name and also as branded products of other major multinationals. Our client has 50% growth forecasted year on year sales for the next 3 years. To facilitate this rapid growth, our role was to enable the organisation to streamline its current value streams through the EI LeanPlus program.
The Programme objectives were:

  • To release at least €1M in additional production capacity on a number of critical manufacturing lines by reducing batch changeover times.
  • To achieve at least €100k p.a. savings on material and running costs by reducing waste
  • Improve factory visual appearance

CLS Approach and Changes Implemented:

Working with three cross functional teams, we utilised a Kaizen based approach to map out the process, identify sources of waste and developed and implemented improvement plans. Our action based focus enabled to teams to make changes in the short, medium and long term, resulting in the following changes:

  • Manufacturing Line – Using SMED, changeover times were reduced by 50%
  • Manufacturing Plant – Using the 5 Lean Principles, the average number of daily batches were increased from 2.5 to 3.0
  • Packaging Line – With a focus on the 7 sources of Waste and 5s, the clearance time was reduced from 30 minutes to 20 minutes

Results / Outcomes:

The targets set were exceeded and following were the highlight results:

  • Total additional new throughput capacity of €1.141M achieved
  • Annual running costs reduced by €119.2k
  • Improved factory visual appearance
  • Improve interdepartmental communications
  • Improved GMP (Good Manufacturing Practice) compliance