Application of Lean Six Sigma Tools for Cycle Time Reduction in Manufacturing: Case Study in Biopharmaceutical Industry

Recently, particularly in the highly competitive manufacturing industry, product cost has become a main business concern. By keeping operating expenditures to the minimum, products can be marketed with lower prices, thus promoting the buying power of customers. Consumers always go for high-quality products at affordable prices. Therefore, producers must come up with products with lower possible cost without jeopardizing quality. Many cost-saving measures have been introduced in the industry, and Lean Six Sigma, which consists of many integrated tools, such as process mapping, value stream map, cause-and-effect matrix, and failure mode and effect analysis, is among the most popular. In this study, the Lean Six Sigma tools of DMAIC were applied to determine wastage and to reduce the cycle time production in a biopharmaceutical operation. The data were analyzed using functional process mapping and value analysis. Through a study in one of the selected production areas, a significant result was obtained where approximately 54 % of the overall production cycle is considered as waste or non-value-adding activities that can be readily eliminated. To obtain better result and sustain improvement, a few activities have been introduced, such as special trolley or cart for product transportation, closing of all exposed pipings or tubings with special head cap, installation of one unit heat exchanger to enhance cooling capacity, and room renovation for a wider working area and proper equipment arrangement. In conclusion, Lean Six Sigma is a very good approach in managing waste and variability, and it is also relevant for application to current manufacturing management system. By implementing Lean Six Sigma, the overall company goal of maximizing profit can be materialized.