Streamline Testing and Release for MMF
5
Please insert your Company Logo here, using the Slide master •Concerns / Issues Needing Attention Preliminary Objectives Current Situation & Target To reduce FP testing time in MMF from current avg of 6.89 days to 5 days Company Name: BIOCON LTD Gemba: QUALITY CONTROL-BIOCON CAMPUS GKW Dates: 5 th Nov TO 6th September Project Title: Streamline testing and release for MMF There is variation in FP test times from 3 days to 9 days Consumption of chemical Man power under training Team Name:Immuno Members: (L-R) Applachari,Praveen,Sunil,Vijay and Babu A P D C Month B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B 10 B 11 B 12 B 13 B 14 B 1 B 2 B 3 B 4 5 B 6 B 7 B8 B9 B 10 B 11 B12 B 13 B 14 B 15 B 16 B1 7 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B 10 B 11 B 12 B 13 B 14 4 7 3 4 4 4 3 4 4 2 3 2 2 4 3 4 4 3 5 4 4 5 5 3 2 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 G ood Gebm a QC -IS Lab Objective Testcom pletion days O w ner Vijay Target 5 days KA IZE N PR OGRESS R EVIEW June-A ugust2013 Location C am pus Biocon-G em ba S ource ofD ata Frequency ofupdation E ach batch 0 1 2 3 4 5 6 7 8 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 Batchesw ith in target 1. Background & Targets
-
Upload
kaizeninstituteindia -
Category
Leadership & Management
-
view
6 -
download
1
Transcript of Streamline Testing and Release for MMF
Please insert your CompanyLogo here, using the Slide master
•Concerns / Issues Needing Attention
•Preliminary Objectives
Current Situation & Target
To reduce FP testing time in MMF from current avg of 6.89 days to 5 days
Company Name:
BIOCON LTD
Gemba:
QUALITY CONTROL-BIOCON CAMPUS
GKW Dates:
5th Nov TO 6th September
Project Title: Streamline testing and release for MMF
There is variation in FP test times from 3 days to 9 days
Consumption of chemical
Man power under training
Team Name:ImmunoMembers: (L-R) Applachari,Praveen,Sunil,Vijay and Babu
A
P
D
C
Month
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B15 B16B17
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14
4 7 3 4 4 4 3 4 4 2 3 2 2 1 2 4 3 3 4 4 2 5 3 4 4 4 4 4 4 3 2 5 5 4 5 4 4 3 5 5 4 3 4 25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
GoodGebma QC - IS Lab
Objective Test completion days Owner Vijay Target 5 days
KAIZEN PROGRESS REVIEW June-August2013 Location Campus
Biocon- Gemba Source of DataFrequency of updation Each batch
0
1
2
3
4
5
6
7
8
B 1
B 2
B 3
B 4
B 5
B 6
B 7 B8 B9 B10
B11
B12
B13
B14
B 1
B 2
B 3
B 4
B 5
B 6
B 7 B8 B9 B10
B11
B12
B13
B14
B15
B16
B17
B 1
B 2
B 3
B 4
B 5
B 6
B 7 B8 B9 B10
B11
B12
B13
B14
Batc
hes
with
in t
arge
t
1. Background & Targets
Please insert your CompanyLogo here, using the Slide master
2. Data Collection & AnalysisConcerns / Problems needing attention :
1.Large variations in test completion days.2.Average = 6.9 Days3.High consumption of chemicals
Please insert your CompanyLogo here, using the Slide master
3. Before After Process MappingProcess mapping - Before
Handlers Day-1 Day-2 Day-3 Day-4 Day-5 Day-6 Day-7
Prodn
QA
QC-Micro
QC-AnalyticalProcess mapping - After
Handlers Day-1 Day-2 Day-3 Day-4 Day-5 Day-6 Day-7
Prodn
QA
QC-Micro
QC-Analytical
PRF Generation
Inspection
Sampling
Analysisplaning
Tests-1,2
Tests-3,4,5 Tests-6,7,8 Tests-9,10,11
Tests-12,13
Review
Prior intimation to QC & QA
Planning, Prioritization
PRF Generation,Intimation
Inspection
Sampling
Analysisplaning
Tests-1,2,3
Tests-4,5,6 Tests-7,8,9 Tests-10,11,12
Tests-13
Review
Please insert your CompanyLogo here, using the Slide master
4. Results & non monetary benefits
4
Control Point Before Kaizen
Target After Kaizen
% Improved
One time Financial Benefit
Annual Benefit (Money Value)
Av. % Batches within 5 days
37 100 88 51
Check Points
Batch completion days 6.9 5
5’S’ Audit score 60& 90% 90% 30
Capacity in No of batches per month
20 25 25 33
Target vs Result Trend Graph – Control Point
Improved work place
Team spirit
•Non Monetary Benefits
Month
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B15 B16B17
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14
4 7 3 4 4 4 3 4 4 2 3 2 2 1 2 4 3 3 4 4 2 5 3 4 4 4 4 4 4 3 2 5 5 4 5 4 4 3 5 5 4 3 4 25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
GoodGebma QC - IS Lab
Objective Test completion days Owner Vijay Target 5 days
KAIZEN PROGRESS REVIEW June-August2013 Location Campus
Biocon- Gemba Source of DataFrequency of updation Each batch
0
1
2
3
4
5
6
7
8
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10
B11
B12
B13
B14 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10
B11
B12
B13
B14
B15
B16
B17 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10
B11
B12
B13
B14
Batch
es w
ith in
targ
et
Please insert your CompanyLogo here, using the Slide master
5. Monitoring through Gemba & Obeya graphs
5
•Double click on sheet to edit
Month
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14 B15 B16B17
B 1 B 2 B 3 B 4 B 5 B 6 B 7 B8 B9 B10 B11 B12 B13 B14
4 7 3 4 4 4 3 4 4 2 3 2 2 1 2 4 3 3 4 4 2 5 3 4 4 4 4 4 4 3 2 5 5 4 5 4 4 3 5 5 4 3 4 25 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
GoodGebma QC - IS Lab
Objective Test completion days Owner Vijay Target 5 days
KAIZEN PROGRESS REVIEW June-August2013 Location Campus
Biocon- Gemba Source of DataFrequency of updation Each batch
0
1
2
3
4
5
6
7
8
B 1
B 2
B 3
B 4
B 5
B 6
B 7 B8
B9
B1
0
B1
1
B1
2
B1
3
B1
4
B 1
B 2
B 3
B 4
B 5
B 6
B 7 B8
B9
B1
0
B1
1
B1
2
B1
3
B1
4
B1
5
B1
6
B1
7
B 1
B 2
B 3
B 4
B 5
B 6
B 7 B8
B9
B1
0
B1
1
B1
2
B1
3
B1
4
Bat
che
s w
ith
in t
arge
t
YearObjective
Gebma Owner
Nov/12 Dec/12 Jan/13 Feb/13 Mar/13 Apr/13 May/13 Jun/13 Jul/13 Aug/13 Sep/13 Oct/13 Nov/13 Dec/13
56% 92% 70% 55% 92% 100% 100% 93% 100% 100%80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 80% 80%98% 99% 97% 100% 100% 100% 100% 100% 100% 100%
100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
KAIZEN PROGRESS REVIEW 2013No of test with in target days
GoodQC - IS Lab Vijay
Biocon- Obeya 5th of every monthSource of Data
Campus80% with in 5days
100 % with in 7 days
Location
Target
frequency of updation
0%
20%
40%
60%
80%
100%
120%
Nov/12 Dec/12 Jan/13 Feb/13 Mar/13 Apr/13 May/13 Jun/13 Jul/13 Aug/13 Sep/13 Oct/13 Nov/13 Dec/13
Ba
tch
es w
ith
in
ta
rg
et
