Farmak

Lean Operational Excellence Pilot Case Study

JSC “Farmak” is the leader of the Ukrainian pharmaceutical market and the largest exporter of medicinal products since 2010. With 20 GMP-compliant production lines and 14 lines certified by the European regulatory authority, Farmak holds its processes to the highest European and US standards. However, understanding business challenges and wishing to move forward, they partnered with Lean Coaching Europe to start their journey into building Lean Organisation.

PROBLEM

– Pharmaceutical industry requirements ask for a significant load of documentation (verification and validation processes).

– Lean approaches have to align with GMP standards; creative ways to implement Lean should be developed especially in restricted processing areas (aseptic areas).

– Boost continuous improvement culture and assure achievement of business targets via Lean tools implementation and employee engagement. 

– Assure “success story” of Lean implementation to launch expansion on to other departments. ​

SOLUTION

  • Change agents and people development 
  • Factory of Ideas and Problem-solving boards 
  • Focused improvement 
  • Project management 
  • Shopfloor management (including KPI cascade) 
  • AM and PM
  • Achieving targeted improvement in Lean culture implementation, OEE increase, self-cost reduction, headcount optimisation and productivity increase)​

RESULTS

  • OEE increase by 18% on average (from 40% to 58%, from 49% to 65%, etc.)​
  • Changeover time reduction by 33%
  • Productivity increase by 15%
  • 9 certified White and Yellow belt change agents
  • Savings of over 60 kEUR by the joint effort of 15 FI teams in three months
  • 3 Visual centers established to streamline CI teams. Average quality of meetings over 80%.
  • Tagging methodology implemented, over 60 abnormalities found, 80% fully eradicated