Due to increased demand, one of the world’s leading manufacturers of generic pharmaceuticals needed a 30 percent rise in throughput at its highest-volume, most complex production site in the Americas. The Powers Company developed a perfect quarterly production schedule and a replicable “rhythm wheel” process that optimizes asset utilization, ensures the right amount of inventory to satisfy market requirements, and links floor-level behavior and processes to management systems.
Our client is a global, integrated specialty pharmaceutical company that produces and markets generic, branded, biosimilar and OTC products spanning the full array of delivery formulations. Following several acquisitions, company leaders wanted to optimally leverage its investments at its No. 1 production site in the Americas. With some 76 different product families, this manufacturing facility is one of the most complex in the company – and in the industry.
The client sought to increase the plant’s throughput 30 percent using its existing technology. They needed to improve asset utilization and ensure it had the right amount of inventory to support customer needs. This would require a structured, thorough production schedule that incorporated the correct standards, operating procedures and behaviors to support planning while defining the proper sequence for the production centers. Work was currently being scheduled and performed on a 7-day schedule simply based on equipment availability. The only way to determine how much product the plant could handle was to assess its current capacity and develop an optimal – but elusive – “rhythm wheel” schedule.