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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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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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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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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5. Current Condition

• Receiving Labels

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• Issuing labels

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• Returning Labels

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6. Cause Investigation

• Process Value Stream Map

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Manual Process steps

Cycle time

Remove NVA added steps


Manual Process steps

Cycle time


Value Graph

7. Counter Measures

• Introduction of technology

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• Label storage with bar code system

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8. Results

Cycle times

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

• Improved manual process after removing NVA steps

13 steps manual process


• Improved Process introducing the Barcode Scanner

6 steps


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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9. Follow Up Plan:

• Monitoring and sustaining the gains

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• Questions

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

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