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This Lean case study illustrates quick changeover, as applied to pharmaceutical blister packing.
BACKGROUND
This company was the 2nd largest manufacturing company in New Zealand in mid 1990's with 5 different plants, producing Pharmaceuticals, Cosmetics, Toiletries, Chemicals, and Food products. Being a pharmaceutical plant, it used to follow strict GMP (Good Manufacturing Practices) which meant that, it had a robust systems and practices including documentation.
SITUATION
The Uhlmann blister packing machine in the pharmaceutical plant was a bottleneck and the company was unable to meet customer demands due to large changeover times. The line setters used to take anything from 4 to 8 hours for setting up the machine and this used to happen 2 to 3 times per week. The machine was run over 2 shifts. The changeovers were done between products and had to meet the pharmaceutical industry standards.
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Source: Best Practices in Lean Case Study, Quick Changeover PDF: Quick Changeovers Case Study PDF (PDF) Document, OpEx Academy NZ
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Lean Management Operational Excellence Lean Culture Lean Game Kanban RCM Autonomous Maintenance Total Productive Maintenance Corporate Culture Kaizen Lean Office Process Improvement Sales & Operations Planning Quick Changeover Good Manufacturing Practice Manufacturing Just in Time
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