Lean Transformation

JSC “Farmak” is the leader of the Ukrainian pharmaceutical market and the largest exporter of medicinal products since 2010. With 22 GMP-compliant production lines and 14 lines certified by the European regulatory authority, Farmak holds its processes to the highest European and US standards

"On behalf of Farmak JSC and on my own behalf, I want to thank Lean Coaching team for successful collaboration in 2020-2021 and express my confidence in even larger achievements towards building Lean culture and implementing advanced TPM practices in 2022. When launching Shopfloor Excellence program, we relied on staff coaching, and during the project we were more than once convinced of the professionalism, high technical and leadership expertise of Lean Coaching consultants, as well as their ability to creatively approach the most challenging tasks."
Pavlyk Pavlo Mykolaevitch
COO

Problem

Reducing COGS via cultural changes in compliance with the existing Lean program

Solution

  • Implementation of Shop Floor Management
  • Implementation of Focused Improvement
  • Lean capability development via engagement of the production staff
  • Implementation of the Autonomous
  • Planned maintenance

Results

  • Self cost improved by 5%
  • Production capacity increased 30%
  • Waste reduced by 1.5%
  • 75% employees develop and engaged in the CI processes
  • Introduced a factory of ideas which now generates > 1.5 ideas per person per year
  • Increase in production staff who role-model their leaders
  • OEE increased from 45% to 60%
  • Reduced short stops by 25%

Lean Transformation

JSC “Farmak” is the leader of the Ukrainian pharmaceutical market and the largest exporter of medicinal products since 2010.With 22 GMP-compliant production lines and 14 lines certified by the European regulatory authority, Farmak holds its processes to the highest European and US standards

"On behalf of Farmak JSC and on my own behalf, I want to thank Lean Coaching team for successful collaboration in 2020-2021 and express my confidence in even larger achievements towards building Lean culture and implementing advanced TPM practices in 2022. When launching Shopfloor Excellence program, we relied on staff coaching, and during the project we were more than once convinced of the professionalism, high technical and leadership expertise of Lean Coaching consultants, as well as their ability to creatively approach the most challenging tasks."
Pavlyk Pavlo Mykolaevitch
COO

Problem

Reducing COGS via cultural changes in compliance with the existing Lean program

Solution

  • Implementation of Shop Floor Management
  • Implementation of Focused Improvement
  • Lean capability development via engagement of the production staff
  • Implementation of the Autonomous
  • Planned maintenance

Results

  • Self cost improved by 5%
  • Production capacity increased 30%
  • Waste reduced by 1.5%
  • 75% employees develop and engaged in the CI processes
  • Introduced a factory of ideas which now generates > 1.5 ideas per person per year
  • Increase in production staff who role-model their leaders
  • OEE increased from 45% to 60%
  • Reduced short stops by 25%