kaizen conference 2019 - cme · 1. company background • bausch health is focused on improving...

Kaizen Conference 2019Bottle labels Tracking system Kaizen

1. Company Background

2. Problem Selection

3. Team Composition

4. Objectives & Approach

5. Current conditions

6. Cause Investigation

7. Counter measures

8. Results

9. Follow up Plan

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Bottle Label Tracking System Kaizen

1. Company Background

• Bausch Health is focused on improving people’s lives with our health care products.

• We manufacture and market a broad range of branded and generic pharmaceuticals, over-the-

counter (OTC) products and medical devices (contact lenses, intraocular lenses, ophthalmic

surgical equipment and aesthetic devices).

• Steinbach facility – 425 Employees

• Packaging Department – 28 Line Operators

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Bottle Label Tracking System Kaizen

2. Problem Selection

• Bottle label receiving, issuing and returning process

• Process

26 steps - manual process

81 min STD lot and 233 min WXL lot

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Bottle Label Tracking System Kaizen

3. Team composition

• Project Leader:

Andria Rempel (Operational Excellence)

• Team Members:

PKG Supervisor

PKG SME

Warehouse/Logistics Supervisor

Compliance Manager

• Team Support:

Director Manufacturing (Kaizen Sponsor)

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Bottle Label Tracking System Kaizen

4. Objective and Approach

• Objectives:

▪ Reduce process time by 50% by removing non-value added steps and introduction of technology.

• Approach:

▪ Team Kaizen using 2-3 hours per week for 7 weeks.

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Bottle Label Tracking System Kaizen

5. Current Condition

• Receiving Labels

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Bottle Label Tracking System Kaizen

• Issuing labels

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Bottle Label Tracking System Kaizen

• Returning Labels

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Bottle Label Tracking System Kaizen

6. Cause Investigation

• Process Value Stream Map

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Bottle Label Tracking System Kaizen

Manual Process steps

Cycle time

Remove NVA added steps

Remove NVA added steps

Manual Process steps

Cycle time

Remove NVA added steps

Value Graph

7. Counter Measures

• Introduction of technology

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Bottle Label Tracking System Kaizen

• Label storage with bar code system

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Bottle Label Tracking System Kaizen

8. Results

Cycle times

• Annual Batch Amounts = 2266 STD Lots / 36 WXL Lots

• Improved manual process after removing NVA steps

13 steps manual process

38 min STD lot and 68 min WXL lot

• Improved Process introducing the Barcode Scanner

6 steps

10 min STD lot and 18 min WXL lot

Cycle time reduction

• Reduced the Label Receiving, Issuing and Returning process by 20 steps

Saving 71 min per STD lot = 88% Time Savings

Saving 215 min per WXL lot = 92% Time Savings

• Total annual savings of 2,810 hrs

• Returning 1.4 Headcount back to packaging line

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Bottle Label Tracking System Kaizen

9. Follow Up Plan:

• Monitoring and sustaining the gains

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Bottle Label Tracking System Kaizen

• Questions

?

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Bottle Label Tracking System Kaizen