Case Study Process optimisation

Efficient Process optimisation at an Austrian pharmaceutical company

An Austrian pharmaceutical company experienced steady growth in recent years, successfully launching new products into the market. However, expanding production capacities posed the challenge of ensuring delivery capabilities, while simultaneously reducing capital commitment.

Industry: Pharmaceuticals

Project period: Nov. 2022 – Feb 2023

Location: Vienne, Austria

Number of consultants involved: 3

Background:

The pharmaceutical company in Austria experienced continuous growth in recent years and successfully introduced new products to the market. With the expansion of production capacities, however, the challenge arose to ensure delivery capabilities and reduce capital commitment at the same time.

Objective:

The consultation using REFA methods aims to uncover potentials in the company’s organisation and management, to optimise warehousing and order production to ensure delivery capabilities and reduce capital commitment.

Approach:

Process optimisation takes place in three steps. In the first step, order processing in area under investigation is analysed to create transparency in the processes and formulate clear objectives. Irregularities and weaknesses are identified and documented during this phase. The analysis is presented to the client as a report and an interactive HTML document to make information flow transparent. Employees are involved in process documentation, using interviews or workshops to take appropriate account of the interfaces.

Observation results:

• Thematic list of irregularities to depict the current situation
• Documented processes
• Naming of identified potential
• Suggestion for realising the potential

Step 3: Process data acquisition and observation

To obtain a comprehensive picture of production processes with all planned and unplanned time components, process data collection and observation at representative workstations were necessary. The main goal was to identify and evaluate potential improvements in production and assembly processes. The process observation was conducted across all important workstations for at least one day per workstation.

Results of the process data acquisition:

• Thematic list of irregularities to depict the current situation
• Recorded time components for planned and unplanned times in the manufacturing process
• - Causes for inefficient processes and mistakes