Applying Lean Six Sigma Methodology to a Pharmaceutical Manufacturing Facility: A Case Study

This research examines a case study on the implementation of an effective approach to advanced Lean Six Sigma problem-solving within pharmaceutical manufacturing site which manufactures acetaminophen (paracetamol containing pain relief) tablets. Though this was completed in single company, delivers important application and results that can be deployed other such companies. The faced backlogs customer orders due increased demand. Increased demand is brand popularity recognition, product efficacy COVID 19 pandemic intensified for relief tablets already very busy site. With demand, ensure timely deliveries, satisfaction minimize delays, sources productivity losses wastes needed analyzed reduced or eliminated. Manufacturing Packaging line downtime identified as one area concern. goal introduce technique reduce without affecting production required fulfil while increasing quality. utilized integrated LSS methodology identifies, stratifies effectively eliminates non-value adding (waste) activities, by following 7-step customized resulted complete elimination issue under investigation savings just half million dollars. learnings are being leveraged worldwide across organizations parent sister sites. presented demonstrated tools accurate root causing problems enablers continuous improvement.