Improvement of manufacturing operations at a pharmaceutical company: A lean manufacturing approach

Journal of Manufacturing Technology Management

Volumn 23, Issue 1, 2011, Pages 56-75

  Chowdary, Boppana V ^a   George, Damian ^b  

^a UNIVERSITY OF THE WEST INDIES   (Trinidad and Tobago)

^b Trincity Industrial Estate   (Trinidad and Tobago)

Author keywords

5 whys; 5S; Cellular manufacturing; Cycle time; Inventory management; Lean manufacturing; Lean production; Manufacturing systems; Pharmaceuticals industry; Trinidad and Tobago; Value stream mapping

Indexed keywords

5-WHYS; 5S; CYCLE TIME; INVENTORY MANAGEMENT; LEAN MANUFACTURING; LEAN PRODUCTION; MANUFACTURING SYSTEM; PHARMACEUTICALS INDUSTRY; TRINIDAD AND TOBAGO; VALUE STREAM MAPPING;

AGILE MANUFACTURING SYSTEMS; CELLULAR MANUFACTURING; INVENTORY CONTROL; QUALITY CONTROL;

INDUSTRY;

EID: 82955207650     PISSN: 1741038X     EISSN: None     Source Type: Journal    
DOI: 10.1108/17410381211196285     Document Type: Article

References (62)

1. Achanga, P., Shehab, E., Roy, R. and Nelder, G. (2006), "Critical success factors for lean implementation within SMEs", Journal of Manufacturing Technology Management, Vol. 17 No. 4, pp. 460-71.
2. Albert, M. (2004), "Setup reduction: at the heart of lean manufacturing", Modern Machine Shop, Vol. 76 No. 11, pp. 66-73.
3. Anand, G. and Kodali, R. (2008), "Selection of lean manufacturing systems using the PROMETHEE", Journal of Modelling in Management, Vol. 3 No. 1, pp. 40-70.
4. Anand, G. and Kodali, R. (2009), "Selection of lean manufacturing systems using the analytic network process - a case study", Journal of Manufacturing Technology Management, Vol. 20 No. 2, pp. 258-89.
5. Angra, S., Sehgal, R. and Noori, Z.S. (2008), "Cellular manufacturing - a time based analysis to the layout problem", International Journal of Production Economics, Vol. 112, pp. 427-38. (Pubitemid 351179615)
6. Barla, S.B. (2003), "A case study of supplier selection for lean supply by using a mathematical model", Logistics Information Management, Vol. 16 No. 6, pp. 451-9.
7. Berry, I.R. (2008), The Pharmaceutical Regulatory Process (Drugs and the Pharmaceutical Sciences), 2nd ed., Informa HealthCare, London.
8. Black, J.T. (2007), "Design rules for implementing the Toyota production system", International Journal of Production Research, Vol. 45 No. 6, pp. 3639-64.
9. Braglia, M., Carmignani, G. and Zammori, F. (2006), "A new value stream mapping approach for complex production systems", International Journal of Production Research, Vol. 44 No. 18, pp. 3929-52. (Pubitemid 44181131)
10. Brown, C.B., Collins, T.R. and Edward, L.M. (2006), "Transformation from batch to lean manufacturing: the performance issues", Engineering Management Journal, Vol. 18 No. 2, pp. 3-14.
11. Chen, J.C., Li, Y. and Shady, B.D. (2010), "From value stream mapping toward a lean/sigma continuous improvement process: an industrial case study", International Journal of Production Research, Vol. 48 No. 4, pp. 1069-86.
12. Choudhury, A.K., Tiwari, M.K. and Mukhopadhyay, S.K. (2004), "Application of an analytical network process to strategic planning problems of a supply chain cell: case study of a pharmaceutical firm", Production Planning and Control: The Management of Operations, Vol. 15 No. 1, pp. 13-26.
13. Dolcemascolo, D. (2008), "Achieving one-piece flow", Reliable Plant Magazine, December, available at: www.reliableplant.com/Read/14703/one- piece-flow
14. Eatock, J., Dixon, D. and Young, T. (2009), "An exploratory survey of current practice in the medical device industry", Journal of Manufacturing Technology Management, Vol. 20 No. 2, pp. 218-34.
15. Erlach, K. (2005), "Rapid and agile production by value stream oriented factory planning", Proceedings of the 1st International Conference on Changeable, Agile, Reconfigurable and Virtual Production CARV, Munich.
16. Greene, A. and O'Rourke, D. (2006), "Lean manufacturing practice in a cGMP environment", Pharmaceutical Technology Europe, Vol. 18 No. 10, pp. 33-40.
17. Haque, B. and James-moore, M. (2004), "Applying lean thinking to new product introduction", Journal of Engineering Design, Vol. 15 No. 1, pp. 1-31. (Pubitemid 38127448)
18. Hobbs, D.P. (2004), Lean Manufacturing Implementation: A Complete Execution Manual for any Size Manufacturer, J. Ross Publishing, Fort Lauderdale, FL.
19. Huang, C.-C. and Liu, S.-H. (2005), "A novel approach to lean control for Taiwan-funded enterprises in mainland China", International Journal of Production Research, Vol. 43 No. 12, pp. 2553-75. (Pubitemid 41633039)
20. Hunter, S.L. and Black, J.T. (2007), "Lean remanufacturing: a cellular case study", Journal of Manufacturing Systems, Vol. 6 No. 2, pp. 129-44. (Pubitemid 351177392)
21. Hyer, N. and Wemmerlöv, U. (2002), "Reorganizing the factory: competing through cellular manufacturing", Productivity Press, Portland, OR.
22. Khamis, N., Rahman, M.N.A., Jamaludin, K.R., Ismail, A.R., Ghani, J.A. and Zulkifli, R. (2009), "Development of 5S practice checklist for manufacturing industry", Proceedings of the World Congress on Engineering 2009, Vol. I WCE 2009, London, July 1-3.
23. Kocakulah, M.C. and Upson, J. (2005), "Cost analysis of computerized physician order entry using value stream analysis: a case study", Research in Healthcare Financial Management, available at: http://findarticles.com/p/ articles/mi-hb1381/is-1-10/ai-n29235839/? tag=content;col
24. Lasa, I.S., Castro, R.D. and Laburu, C.O. (2009), "Extent of the use of Lean concepts proposed for a value stream mapping application", Production Planning and Control, Vol. 20 No. 1, pp. 82-98.
25. Lau, H.Y.L. and Mak, K.L. (1999), "A unified framework for the development of automated manufacturing systems supervisory software for the pharmaceutical industry", International Journal of Computer Integrated Manufacturing, Vol. 12 No. 3, pp. 193-210. (Pubitemid 129606885)
26. Lee, L.C. (1985), "A study of system characteristics in a manufacturing cell", International Journal of Production Research, Vol. 23 No. 6, pp. 1101-14. (Pubitemid 15599265)
27. Lian, Y.-H. and Landeghem, H.V. (2007), "Analysing the effects of Lean manufacturing using a value stream mapping-based simulation generator", International Journal of Production Research, Vol. 45 No. 13, pp. 3037-58. (Pubitemid 46782039)
28. Logendran, R. (1998), "A methodology for transferring research experiences in design and scheduling of cellular manufacturing systems", Journal of Engineering Education, Vol. 87 No. 5, pp. 507-9.
29. Lummus, R.R., Vokurka, R.J. and Rodeghier, B. (2006), "Improving quality through value stream mapping: a case study of a physician's clinic", Total Quality Management and Business Excellence, Vol. 17 No. 8, pp. 1063-75. (Pubitemid 44831475)
30. McDonald, T., Aken, E.M.V. and Rentes, F.A. (2002), "Utilising simulation to enhance value stream mapping: a manufacturing case application", International Journal of Logistics Research and Applications: A Leading Journal of Supply Chain Management, Vol. 5 No. 2, pp. 213-32.
31. Mark, A. (2004), "Setup reduction: at the heart of lean manufacturing", Modern Machine Shop, Vol. 76 No. 11, pp. 66-73.
32. Matt, D.T. (2008), "Template based production system design", Journal of Manufacturing Technology Management, Vol. 19 No. 7, pp. 783-97.
33. Mejabi, O.O. (2003), "Framework for a lean manufacturing planning system", International Journal of Manufacturing Technology and Management, Vol. 5 Nos 5/6, pp. 553-78.
34. Miller, G. (2008), Ensuring Product and Process Quality by Utilising Lean Manufacturing In Your Plant, Pharmaceutical Manufacturing Conference on "Ensuring Compliance And Efficiency for Pharmaceutical Manufacturers", Johannesburg, June 23-25.
35. Mukhopadhyay, S.K., Dwivedy, J. and Kumar, A. (1998), "Design and implementation of an integrated production planning system for a pharmaceutical manufacturing concern in India", Production Planning and Control: The Management of Operations, Vol. 9 No. 4, pp. 391-402. (Pubitemid 128625497)
36. Murray, P. (2009), Mitigating the Risks When Outsourcing Pharmaceutical Manufacturing, European Pharmaceutical Contract Manufacturing 2009, June 30-July 1, Le Meridien Piccadilly, London.
37. Nally, J.D. (2007), Good Manufacturing Practices for Pharmaceuticals, 6th ed., Informa Healthcare, London.
38. Ohno, T. (1988), Toyota Production System, Productivity Press, Cambridge, MA, pp. 1-44.
39. Papadopoulou, T.C. and Ozbayrak, M. (2005), "Leanness: experiences from the journey to date", Journal of Manufacturing Technology Management, Vol. 16 No. 7, pp. 784-807. (Pubitemid 41319594)
40. Pattanaik, L.N. and Sharm, B.P. (2009), "Implementing lean manufacturing with cellular layout: a case study", International Journal of Advanced Manufacturing Technology, Vol. 42, pp. 772-9.
41. Peeters, S. (2008), Design of an Effective Compliance Programme for Excipients Manufacturing European Conference on Good Manufacturing Practices for Pharmaceutical Excipients, 1-2 December, Munich, available at: www.ipecconference.org/daten/training/IPEC-Conference.pdf
42. Praveen, P., Chowdary, B.V., Deshmukh, S.G. and Prasant, P. (2009), "A new approach for formation of virtual cells", International Journal of Manufacturing Research, Vol. 4 No. 2, pp. 171-88.
43. Rahman, S., Laosirihongthong, T. and Sohal, A.S. (2010), "Impact of lean strategy on operational performance: a study of Thai manufacturing companies", Journal of Manufacturing Technology Management, Vol. 21 No. 7, pp. 839-52.
44. Satoglu, S.I., Durmusoglu, M.B. and Ertay, T. (2010), "A mathematical model and a heuristic approach for design of the hybrid manufacturing systems to facilitate one-piece flow", International Journal of Production Research, Vol. 48 No. 17, pp. 5195-220.
45. Saurin, T.A., Marodin, G.A. and Ribeiro, J.L.D. (2010), "A framework for assessing the use of lean production practices in manufacturing cells", International Journal of Production Research, Vol. 48 No. 16, pp. 4215-30.
46. Schaeffer, J.A., Cadavid, J. and Backström, T. (2010), "Spatial design for continuous improvement: the case study of three manufacturing companies", International Journal of Computer Integrated Manufacturing, Vol. 23 No. 8, pp. 791-805.
47. Serrano, I., Ochoa, C. and Castro, R.D. (2008), "Evaluation of value stream mapping in manufacturing system redesign", International Journal of Production Research, Vol. 46 No. 16, pp. 4409-30.
48. Seth, D. and Gupta, V. (2005), "Application of value stream mapping for lean operations and cycle time reduction: an Indian case study", Production Planning and Control: The Management of Operations, Vol. 16 No. 1, pp. 44-59. (Pubitemid 41647053)
49. Seth, D., Seth, N. and Goel, D. (2008), "Application of value stream mapping (VSM) for minimization of wastes in the processing side of supply chain of cottonseed oil industry in Indian context", Journal of Manufacturing Technology Management, Vol. 19 No. 4, pp. 529-50. (Pubitemid 351630006)
50. Slomp, J., Chowdary, B.V. and Suresh, N.C. (2005), "Design of virtual manufacturing cells: a mathematical programming approach", Robotics and Computer-Integrated Manufacturing, Vol. 21 No. 3, pp. 273-88. (Pubitemid 40415257)
51. Stubbs, C. (2008), Assessing The Integration of the Compliance Objectives of the FDA's "Pharmaceutical GMP for the 21 Century" Initiative With The Business Objective of Increasing Efficiency and Reducing Costs, Pharmaceutical Manufacturing Conference on "Ensuring Compliance and Efficiency For Pharmaceutical Manufacturers", Johannesburg, June 23-25.
52. Suárez-Barraza, M.F. and Ramis-Pujol, J. (2010), "Implementation of Lean-Kaizen in the human resource service process: a case study in a Mexican public service organization", Journal of Manufacturing Technology Management, Vol. 21 No. 3, pp. 388-410.
53. Taj, S. (2008), "Lean manufacturing performance in China: assessment of 65 manufacturing plants", Journal of Manufacturing Technology Management, Vol. 19 No. 2, pp. 217-34. (Pubitemid 351270058)
54. United Nations (2009), Guidance for the Implementation of a Quality Management System in Drug Testing Laboratories: A Commitment to Quality and Continuous Improvement, United Nations, New York, NY.
55. Vinodh, S., Arvind, K.R. and Somanaathan, M. (2010), "Application of value stream mapping in an Indian camshaft manufacturing organization", Journal of Manufacturing Technology Management, Vol. 21 No. 7, pp. 888-900.
56. WHO (2010), "Who expert committee on specifications for pharmaceutical preparations", Technical Report Series, WHO Technical Report Series 957, WHO, Geneva, available at: www.who.int/medicines/publications/ TRS957-2010.pdf
57. Womack, J.P., Jones, D.T. and Daniel, R. (2007), The Machine That Changed The World, The Free Press, New York, NY.
58. Yang, T.-M. and Su, C.-T. (2007), "Application of Hoshin Kanri for productivity improvement in a semiconductor manufacturing company", Journal of Manufacturing Technology Management, Vol. 18 No. 6, pp. 761-75.
59. Yusuf, Y.Y. and Adeleye, E.O. (2002), "A comparative study of lean and agile manufacturing with a related survey of current practices in the UK", International Journal of Production Research, Vol. 40 No. 17, pp. 4545-62.
60. Bhasin, S. (2006), "Lean viewed as a philosophy", Journal of Manufacturing Technology Management, Vol. 17 No. 1, pp. 56-72. (Pubitemid 41811033)
61. Christopher, M., Towill, D.R., Aitken, J. and Childerhouse, P. (2009), "Value stream classification", Journal of Manufacturing Technology Management, Vol. 20 No. 4, pp. 460-74.
62. Kim, T. (1985), "Just-in-time manufacturing system: a periodic pull system", International Journal of Production Research, Vol. 23 No. 3, pp. 553-62. (Pubitemid 15541570)