Efficiency Optimization Projects in Packaging and Interim Head of Department
Company:
not disclosed
Role:
Efficiency Optimization Projects in Packaging and Interim Head of Department
Industry:
Pharma
Revenue:
> 5 Billion €
Employees:
Approx. 19,000
Timeline:
10/2023 – 12/2024
Situation:
Global pharmaceutical Company
Manufacturing and packaging site for Solids and oncology products
(100 M Blister / 2 B Tabs)
Location:
Tokio, Japan (global), Munich area (local)
Context:
- Department results not meeting expectations
- Missing transparency on results and root causes for deviations
Task:
- As-is analysis of personnel, performance development, processes and use of lean tools
- Development and alignment of the target picture for process and organizational adjustments
- Creation and execution of implementation plan
Actions:
- KPI-focused alignment of the organization (all levels)
- Establishment of a cross-functional lead team
- Reorientation of shop floor routines, especially tier meeting cascade
- Introduction of a continuous operator training system
- Development of an adapted 3-shift model with HR and works council
- Hiring and training concept developed and implemented
Results:
- Joint alignment of management and employees on KPIs achieved – including consistent visualization
- Weekly blister output increased by 32% from Q1 to Q4
- Open positions filled almost completely – new employees can operate equipment independently
- Critical processes standardized – with distributed process ownership
Special Challenges:
- Interim leadership of department (01/2024 – 04/2024) during vacancy