《Applying_Lean_Tools_and_Techniques》.pdf

Applying Lean Tools and Techniques in Pharmaceutical Environments Abstract: Due to its origin, lean has mostly been widely applied to manufacturing focused companies, especially in automotive and aerospace industries. With some pre-planning and industry-specific considerations, these same tools and concepts can also be applied in other businesses as well. In this article, we present some guidelines for a successful implementation of lean tools and techniques in life science industry. The overall objective of any lean initiative is to identify and eliminate waste (“muda”). Waste comes in many forms: 1. unnecessary human motion, 2. conveyance of product, 3. over- production, 4. inventory, 5. space, 6. over- processing, 7. waiting and 8. improper-utilization of talent. Common lean tools and general guidelines are presented below for successfully identifying each of these wastes in a life-science environment. Although strict regulatory issues often cause delays and make it more difficult to implement changes for pharmaceutical companies, these lean concepts and tools have been applied successfully in numerous organizations. Unnecessary Human Motion The single most useful tool for identifying and eliminating (as much as we can) this type of waste is what we refer to as a “spaghetti diagram”. This technique involves following a specific person for a minimum of 30 minutes to a maximum of two hours. To ensure proper results, first explain to the group (whether it be production, lab, etc.) what is being done and why. Secondly, explain clearly to the person(s) being followed that we are evaluating our processes and the layout, not the individual(s). The path taken by the individual(s) should be clearly marked on a layout. The results should be shared for accuracy and buy-in. As you conduct the spaghetti diagram, strictly adhere to the following guidelines: • Note the date, ti