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