improvement projects 2008
TRANSCRIPT
Page: 1, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
New Packaging Line - Cambé
Description of status after implementation•Direct Labor reduction (Reduction of 16 and avoidance of 8 FTEs)
•Insource of Alu x Alu packaging
•Increase of packaging flexibility and decrease of TPC (Alu x Alu forming station)
•Avoidance of quality complaints (quality improvement)
Saving CategoryDirect Labor reduction / Insource of 3rd party packaging
Status before implementation
• Old-fashioned primary packaging line (Blipack 204) with impact on frequent customers complaints due to the lack of vision system requiring manual inspection of 100% of the blisters
• Manual secondary packaging line requiring a large number of FTEs
• Outsourcing of Alu x Alu blistering because Blipack 204 does not have forming station for Alu x Alu blisters
• Additional FTEs would be required with the current setup to serve long term volume increase
Page: 2, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
New Packaging Line - Cambé
How we did it / once off costAcquisition of one full packaging line (primary and secondary) in order to eliminate existing Blipack 204, some secondary manual packaging and third party operation / Mio US$ 1,409
Date of implementation, responsible local project managerJan/09, Frederico Giunchetti (Engineering Head)
Annualized savings•Reduce of third party costs
•Headcount cost savings
•Headcount avoidance (Additional shifts)
Total savings:Th US$ 836/year
Page: 3, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
Packaging Outsourcing - Cambé
Saving Category 3rd party manufacturing
Status before implementation
Sandoz FTEs performing manual packaging of displays and operating the bottles filling equipment
Description of status after implementation Displays primary and secondary packaging outsourcing
Cost reduction with headcounts
Liberation of physical space to a new packaging equipment
How we did it / once off costOutsourcing products with low production and large quantity of FTEs / Th US$ 0
Date of implementation, responsible local project managerFeb, Sep, and Nov/08, Wilson Gonçalves (Packaging Head)
Annualized savingsTh US$ 64/year
Page: 4, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
Performance Increase (OEE) - Cambé
Saving Category Lean / OEE
Status before implementation Poor performance measurement and lack of improvement initiatives
OEE TABLETING 20,7% YTD 2007
OEE PACKAGING 26,5% YTD 2007
Description of status after implementation Implementation of performance KPIs and Process Improvement team
OEE TABLETING 41,8% (YTD SEP/08)
OEE PACKAGING 40,6% (YTD SEP/08)
How we did it / once off cost Better products allocation in packaging equipment,
Shop floor production planning,
TPM (Total Productive Maintenance) implementation
Small focused improvements on the equipment
Cost of Th US$ 57/year (TPM Consultancy)
Page: 5, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
Performance Increase (OEE) - Cambé
Date of implementation, responsible local project managerMar/08, Frederico Giunchetti (Engineering Head)
Annualized savingsImproving the Production Performance (Manufacturing and Packaging) in 2008, we have avoided 23 new
FTEs to perform the 2008 Volumes considering the 2007 performance
Total savings: Th USD 246/year
Packaging
37
45
0,39
0,46
26,5
40,6
-5
101520253035404550
2007 2008
Mio
Pac
ks,
OE
E%
0,34
0,36
0,38
0,40
0,42
0,44
0,46
0,48
Mio
Pac
ks/
FT
E
Volume Volume / FTE OEE
Temp. 9 11
0,39
FTE 95,5 116,1
Tableting
1.041
689
80,1
58,4
20,7
41,8
-
200
400
600
800
1.000
1.200
2007 2008
Mio
SD
U
-
10,0
20,030,0
40,0
50,0
60,070,0
80,0
90,0
OE
E%
, M
io S
DU
/FT
E
Volume Volume / FTE OEE
Page: 6, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
Throughput Time Reduction - Cambé
Saving CategoryLean / OEE
Status before implementation Total TPT in days: 45 days YTD 2007
Description of status after implementation Total TPT in days: 27,6 days YTD SEP/08
How we did it / once off cost A large number of improvement actions were implemented:
Tight inventory policy,
Better sales forecast accuracy,
Improvement in the Manufacturing and Packaging planning,
OEE measurement implementation,
Multi-disciplinary team focusing on troubleshooting, etc.
Date of implementation, responsible local project managerJan/08, Frederico Giunchetti (Engineering Head)
Page: 7, DRIVE Project – Projects of Common Interest – Sandoz Cambe / Frederico Giunchetti
Throughput Time Reduction - Cambé
Annualized savings