Improving Packing Line Efficiency by increasing OEE (Overall Equipment Efficiency) and MTBF (Mean Time Between Failure) in a pharmaceutical manufacturing site
Director Operations, Site Leader, General Manager
Company: Started at P&G, continued at Warner Chilcott Deutschland GmbH
Role:
Initially Director Operations (at P&G), later Site Leader & General Manager (at WCD)
Industry:
Pharmaceuticals
Situation:
Output of packing lines too low
Responsibility:
- Director Operations: 70 FTE in Packaging Department
Context:
- Increase OEE longterm from 20 % to 85% (Standard Goal at P&G)
- Increase MTBF longterm from 2 minutes up to 240 minutes (Standard Goal at P&G)
Actions:
- Day-to-day focus on line performance
- Increase capabilities of shop floor staff
- Application of multiple Autonomous Maintenance und Preventive Maintenance Tools (SMED, Work Point Analysis, 5S, Problem Solving, Shop Floor Management/ Daily Direction Setting)
- Implementation of systematic escalation process with support areas
Result:
- Benchmark results for OEE and MTBF for packing lines in pharmaceuticals achieved
- OEE = 65% and MTBF = 120 minuten (Achieving higher numbers did not make sense from a business point of view)
- Packing Lines run with high efficiency and highly predictability (less then 5 % unplanned downtime), therefore line staffing could be reduced and output increased
Special Challenges:
Optimizing the high numbers of small production order, which account for a large portion of downtime due to change overs in the pharmaceutical industry