Effective implementation of Lean SixSigma and 5s in pharma manufacturing

Rajkumar Shirodkar, Sr VP, Sovereign Pharma spoke on effective implementation of Lean Six Sigma and 5s in pharma manufacturing at Daman Pharma Summit 2023. Shirodkar, a Black Belt in Lean and Six Sigma, drew from his experience in delivering significant financial benefits under lean and six sigma methodology and expertise in 5S concept and process excellence, and shared several valuable insights with the audience.

He explained that the concept of lean production was pioneered by Toyota in the 60s and adopted by other Japanese manufacturers. Discovered later by western manufacturers in the 80s, it is known by many names: Toyota Production System, Just-In-Time, Lean Production etc. Though it was originally focused on manufacturing, now it is also ap- plied to transactional and service environments.

He informed that Six Sigma is a disciplined, customer-cen- tric, data-driven approach and methodology for reducing process variation and eliminating defects. Speaking on 5S, he explained that it is actually systematic organisation of the working space with goal of eliminating muda

He went to explain the various tools, methods and applications of these concepts. He also elaborated on quantitative and qualitative benefits of adopting these concepts in the pharma industry such as increase in employees’ productivity, reduction of cycle time, production time and cost of purchased material, reduction of machines breakdowns, increase in quality and process stability, improvement in material control and health & safety, increase in available space for workplace etc. He also highlighted that a clean and tidy workplace leads to greater well being, increased motivation and improvement in the company’s image.