OEE and Output Improvement for a Pharma and Medtech Manufacturer
Pharma and medtech manufacturer with manual assembly
A pharma and medtech manufacturer struggled with high downtime in largely manual assembly processes, resulting in output that fell short of market demand.
The challenge
The situation
A pharma and medtech manufacturer suffered from high downtime and loss times in its largely manual assembly processes, resulting in output that fell short of market demand. A lack of resource planning and ineffective bottleneck management further compounded the production inefficiencies.
Our approach
What we delivered
Structured OEE measurement and control with systematic root-cause analysis for downtime
Resource planning and workforce flexibilisation through cross-training programmes
Integrated production management with communication loops and coordinated planning tools for bottleneck control
The outcome
Results & impact
20% more production output
Increase in production output of 20 percent.
1 sustainable change mentality
Performance-oriented change culture established across the organisation.
0 unplanned downtime
Unplanned downtime significantly reduced through structured root-cause analysis.
3 process improvement initiatives
Optimisation, process improvement and cost reduction implemented as initiatives.
In summary
The manufacturer increased production output by 20 percent and established a sustainable, performance-oriented change culture, with unplanned downtime significantly reduced.
Related expertise
Lean Manufacturing →
Systematic root-cause analysis of downtime and a 20 percent increase in production output in largely manual assembly processes are classic lean manufacturing levers for raising efficiency.
Continuous Improvement Programs →
The three initiatives implemented - optimisation, process improvement and cost reduction - together with the performance-oriented change culture established in the organisation show how continuous improvement becomes sustainably embedded.
Lean Six Sigma →
Structured OEE measurement and control with systematic root-cause analysis of downtime follows the data-driven root-cause methodology used in the Lean Six Sigma approach.
Manufacturing & Supply Chain Management →
Resource planning with cross-training of the workforce and integrated production management with coordinated planning tools for bottleneck control are core components of effective production management across the manufacturing chain.
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Sources
- Entourage project experience (anonymised)
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