A CASE STUDY ON LEAN SIX SIGMA FOR REDUCTION IN CHANGEOVER TIME OF DRY GRANULATION AREA IN LEADING PHARMACEUTICAL COMPANY

Mohd Ahsan Khan*, Priyadarshan Pachorkar, Zeba Khan

Company XYZ is facing potential drop in throughput of roll compactor batches due to high changeover time for utilization of dry granulation area. To resolve this problem company has targeted 20% reduction in changeover time. Reduction in changeover will leads to the availability of machinery for longer period result in a production improvement. To implement this project following activities are carried out in company. Time motion study of the casual & operator involve in cleaning, analysis of changeover time & drawn of I-MR chart with reference to 3 sigma level of the process, implementation of engineering controls, implementation of 4S and 5S principle. On implementation of these changes in pilot study 43% reduction in changeover time has been achieved.