Lean Management

Swapnil Vashishtha

Project Trainee

Sanofi India Ltd

Contents

• Opening vignette

• Lean implementation

• Tools and techniques

• Key Learning's

• Outcome

1 Roll Out in January

2

3

4

5

Prior stage

Partially visible KPI’S

Purely focused on tools

Push model

Departmental Structure

2 Purely focused on tools

1

3

4

5 Partially visible KPI’S

Roll Out in January

Push model

Departmental Structure

Prior stage

3

1

2

4

5

Purely focused on tools

Departmental Structure

Roll Out in January

Push model

Partially visible KPI’S

Prior stage

4 Departmental Structure

1

2

3

5 Partially visible KPI’S

Push model

Purely focused on tools

Roll Out in January

Prior stage

5 Partially visible KPI’S

1

2

3

4 Departmental Structure

Push model

Purely focused on tools

Roll Out in January

Prior stage

Goal

Organogram

• Storage • Quality Check • Approved Storage • Dispensing

• Supplier or API • Packing material

• 14 lines, 5 are dedicated • Offline packing • Blister and strip both • Primary and secondary

• Finished good storage • Quality check • Batch release

• Dispatch to retailers

Validated Forecast

Supply chain and purchase Department

Process Flow

20th May 22nd May 26th May 30th May 3rd august

Team Formation and Training

Simulation for current State Map

Start Realizing

Data CollectionFuture State Map

TIMELINE

A Value Stream is all the actions (both value added and non-value added) required to bring a product to the customer.

It is:

• “Big Picture”, not individual processes

• Improving the whole, not just optimizing

the parts

Packing Distribution Customer

Design Raw Materials Parts ManufacturingRequirements

Cont..

• Peculiar flow for Allegra (product family)

• Raw material storage to shipment of finished goods

• Lean metrics considered• Change over time, • Process time• Cycle time • Set up time• Takt time • Standard number of workers

Microsoft Excel Worksheet

project definition

Unveiling Waste

Constraints and Pitfalls

• Separate map is to be designed for packing material

• Frivolous choice of shared resources

Value Stream Map

5S and Visual management

+ Q D C I sheetsImplementation Plan

Summarization of Visual display sheets

14 1620

24

11 106

2

51015202530

Mar Apr May Jun

Non -Adhare

Adhere 25 26 26 26

0 0 0 0

5

10

15

20

25

30

Mar Apr May Jun

Incident

Target

Q-Sheet (Rejection) Q-Sheet (Quality)

D-Sheet (Plan Adherence) S-Sheet (Safety Sheet)

24 25 26 25

1 1 0 1

51015202530

Mar Apr May Jun

Incident

Target20 22 24 21

5 4 2 5

51015202530

Mar Apr May Jun

Non- Achieved

Achieved

Feeding channel issue

Forming issue, C. Air issue

Spaghetti diagram

• It is a “Physical Process Map”, “Point-to-Point Flow Chart”• “Work-flow Diagram”

Muda: Time invested in searching Bunkers

Lean tools

• Activity value map

• Change over time survey

• Format simplification

• 5S

• Standardization

• Kaizen events

changeOver time Activity value PCT Forms Kaizen

Change Management

Process and Results Total SystemsDo not judge, Do not

BlameProcess and Results Total Systems

Do not judge, Do not Blame

Methods and ToolsMethods and Tools

Customer

SDCA to PDCA

Next Process is

the customer

Quality 1st , securtiy always

Market oriented

approach

Upstream Management

Speak with data

Variability Control

SDCA to PDCA

Next Process is

the customer

Quality 1st , securtiy always

Market oriented

approach

Upstream Management

Speak with data

Variability Control

Employee Engagement Sheet

Total Suggestions = 52

Current Status

• Sample box to be placed in secondary packaging

• Separate space for extra stereo's • Bunker's sleeve ring to be fixed by a

butterfly nob rather than a screw • Improper Printing on FBC by the

supplier turns online printing to offline

• SAP Training to the operators of Warehouse

• Circular Plate for Machine No 3

• Milestone: 200 to 600Kg shredding every day

• Spare Part for C/O in FETTE • Dye changing System for C/O in

Compression

EES

• Closed Cells : Time motion Study

• Motivational Passage

Section 2

Closed Cell : Time Motion Study

Three Aspects for planning a Cell

•Physical Facility

•Operating Procedures

•Personnel (Policies, Leadership and Training)

Time Motion Study

•It demonstrate o Time

o Motion

o Cycle Time

Microsoft Excel 97-2003 Worksheet

Types of Cells

Cells can take different forms based on

•Parts (P)

•Quantity Produced (Q)

•Routing Employed (R)

Flows and their Benefits

Motivational Factor 1

2

3

5

4

SMED : Granulation

Microsoft Excel Worksheet

• Activity Sequencing

• Classification into External and Internal

Root cause

Documented

Lean Forum

• Awareness

• People Management

• Instant gratification

Timeline

12th Sept

Prototype Display

16th Sept

18th SeptUpdating Risk register Approved Change Requests

20th Sept Website Live for deployment

on server

1st Sept

Joomla interface and Wamp Server Web Development will start

Web Site launch for Beta Testingusability and robustness

16.5 15.0 13.6

Plant Cycle Time

May-June July-August YTD

Days

•Sustained Lowest Conversion Cost

Recommendation

• Consolidated Planning

• Manufacturing Layout

• Physical dimension quality check