Pharmaceutical :: Getting Good Results Fast Saves the Plant

Project: A small manufacturing facility - part of a large, global corporation - was in danger of being shut down because of their poor performance. Defects were high, resulting in low yield and high process cycle time. Shipping of finished product took over 30 days because of paperwork delays

Issue: They could not meet their demand for goods (and the goods were already sold!), it was taking them a month to do a week's worth of Regulatory paperwork, and morale was as low as it could get.

Solution: Using the BeeLineResults™ approach of targeting business process improvement efforts to the top 3 projects, limiting training on "the tools needed for the job", and intense coaching, this facility was able to bring itself from a bad situation to a GREAT position within 7 months.

Results: Within 6 weeks, root causes were verified, solutions piloted, and the project was in the final stages of implementation!

Note: During the first 7 months they: Reduced cycle time of paperwork to 25%, reduced equipment failures by over 50%, reduced inspection errors (which resulted in throwing away good product) by 80%, exceeded all of their production goals, improved employee morale, and did so with no major capital or resource investments. Within a year of launching BeeLineResults™, they were being held up by their corporate headquarters as an example to follow!