A
1. Background & Targets
C
P
Project Title: Streamline testing and release for MMF Company Name:
BIOCON LTD
Gemba:
QUALITY CONTROL-BIOCON CAMPUS
D
GKW Dates: 5th Nov TO 6th September
•Preliminary Objectives To reduce FP testing time in MMF from current avg of 6.89 days to 5 days
Team Name:Immuno Members: (L-R) Applachari,Praveen,Sunil,Vijay and Babu
Current Situation & Target
•Concerns / Issues Needing Attention
Source of Data Frequency of updation Location June-August2013
Biocon- Gemba Month
KAIZEN PROGRESS REVIEW Objective Test completion days Gebma
There is variation in FP test times from 3 days to 9 days
Owner
QC - IS Lab
Vijay
Target
Each batch Campus Good
5 days
8
7
6
Consumption of chemical
5
3
2
1
1B 2B B 3B 4B 5B 6B 7B 8B 9 10B B 1B 12B 13B 14B 1B 2B 3B 4B 5B 6B 7B 8B 9 10B B 1B 12B 13B 14B 15B 16B 17B 1B 2B 3B 4B 5B 6B 7B 8B 9 10B B 1B 12B 13B 14
Man power under training
rg in esw atch B
4
0
B1 B2
4 5
7 5
B3
3 5
B4
4 5
B5
4 5
B6
4 5
B7
3 5
B8
B9
4 5
B10 B11 B12 B13 B14 B 1
4 5
2 5
3 5
2 5
2 5
1 5
2 5
B2
4 5
B3
3 5
B4
3 5
B5
4 5
B6
4 5
B7
2 5
B8
B9
5 5
B10 B11 B12 B13
3 5
4 5
4 5
4 5
4 5
B14
B15 B16
4 5
4 5
3 5
B1 7
2 5
B1
5 5
B2
B3
5 5
B4
4 5
5 5
B5
4 5
B6
B7
4 5
3 5
B8
B9
5 5
B10
5 5
B11
4 5
B12
3 5
4 5
B13
B14
2 5
5
5
5
5
5
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5
5
5
5
2. Data Collection & Analysis Concerns / Problems needing attention : 1.Large variations in test completion days. 2.Average = 6.9 Days 3.High consumption of chemicals
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3. Before After Process Mapping Handlers Prodn QA QC-Micro
Process mapping - Before Day-1 Day-2 PRF Generation
Day-3
Day-4
Day-5
Day-6
Day-7
Prior intimation to QC & QA
Inspection
Planning, Prioritization
Sampling
Ana l ysis planing
Tes ts-3,4,5
Tes ts-6,7,8
Tes ts9,10,11
Tes ts12,13
Revi ew
Tes ts-1,2
QC-Analytical Process mapping - After Handlers Day-1 Day-2 Prodn QA QC-Micro
Day-3
Day-4
Day-5
Day-6
Day-7
PRF Generation,Intimation Inspection Sampling Ana l ysis planing
QC-Analytical
Tes ts-1,2,3
Tes ts-4,5,6
Tes ts-7,8,9
Tes ts10,11,12
Tes ts-13 Revi ew
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4. Results & non monetary benefits Control Point
Before Kaizen
Av. % Batches within 5 days
Target
37
100
Batch completion days
6.9
5
5’S’ Audit score
60&
Capacity in No of batches per month
20
After Kaizen
% Improve d
88
51
90%
90%
30
25
25
33
One time Financial Benefit
Annual Benefit (Money Value)
Check Points
Target vs Result Trend Graph – Control Point Source of Data Frequency of updation June-August2013 Location
Biocon- Gemba Month
KAIZEN PROGRESS REVIEW Objective Test completion days Gebma
Owner
QC - IS Lab
Vijay
Target
•Non Monetary Benefits Improved work place
Each batch Campus Good
5 days
Team spirit
8
7
6
5
inrg Batchesw
4
3
2
1
1BB2 B3B4 B5B6 B7B8 B10B1B9 B12B13 B14B1 B2B3 B4B5 B6B7 B8 B10B1B9 B12B13 B14B15 B16B17 B1B2 B3B4 B5B6 B7B8 B10B1B9 B12B13 B14
0
B1 B 2 B3 B4 B5 B6 B7
4 5
7 5
3 5
4 5
4 5
4 5
3 5
B8
B9 B10 B11 B12 B13 B14 B 1 B 2 B 3 B 4 B 5 B 6 B 7
4 5
4 5
2 5
3 5
2 5
2 5
1 5
2 5
4 5
3 5
3 5
4 5
4 5
2 5
B8
B9 B10 B11 B12 B13 B14 B15 B16
5 5
3 5
4 5
4 5
4 5
4 5
4 5
4 5
B1 B1 7
3 2 5 5
5 5
B2
B3
5 5
B4 B5
4 5
5 5
4 5
B6
B7
4 5
3 5
B8
B9
5 5
B10
5 5
B11
4 5
B12
3 5
4 5
B13
B14
2 5
5
5
5
5
5
5
5
5
5
4
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5. Monitoring through Gemba & Obeya graphs Source of Data Frequency of updation June-August2013 Location
Biocon- Gemba Month
KAIZEN PROGRESS REVIEW Objective Test completion days Gebma
Owner
QC - IS Lab
Vijay
Target
Each batch Campus Good
5 days
8
7
6
5
rg in w s e h tc a B
4
3
2
B 1 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 0 1 B 1 B 2 1 B 3 1 B 4 1 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 0 1 B 1 B 2 1 B 3 1 B 4 1 B 5 1 B 6 1 B 7 1 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 0 1 B 1 B 2 1 B 3 1 B 4 1 B
1
0
B1 B2
4 5
7 5
B3
B4
3 5
B5
4 5
B6
4 5
4 5
B7
3 5
B8
B9
4 5
B10
4 5
2 5
B11
B12
3 5
B13
2 5
B14
2 5
1 5
B1
2 5
B2
4 5
B3
B4
3 5
B5
3 5
B6
4 5
B7
4 5
B8
2 5
B9
5 5
B10
3 5
B11
4 5
B12
4 5
4 5
B13
B14
4 5
4 5
B15 B16
4 5
B1 7
3 5
B1
2 5
5 5
B2
B3
5 5
B4
4 5
Biocon- Obeya Year
KAIZEN PROGRESS REVIEW No of test with in target days
Objective Gebma
QC - IS Lab
Owner
N ov/1 2
Ja n/13
Target
Vijay
5 5
B5
4 5
B6
B7
4 5
B8
3 5
B9
5 5
B10
5 5
B11
4 5
B12
3 5
B13
4 5
B14
2 5
5
5
5
5
5
5
5
5
5
Source of Data frequency of updation 5th of every month 2013 Campus Location
80% with in 5days 100 % with in 7 days
Good
1 20%
1 00%
g r n i w s e h c t a B
80 %
60 %
40 %
20 %
0%
Nov/12
56% 80% 98% 100%
De c/12
92% 80% 99% 100%
Dec/ 12
Ja n/13
70% 80% 97% 100%
Feb/13
Fe b/13
55% 80% 100% 100%
Ma r/ 13
Ma r/13
92% 80% 100% 100%
Apr/ 13
Apr/13
100% 80% 100% 100%
Ma y/1 3
May/13
100% 80% 100% 100%
Jun/13
Jun/13
93% 80% 100% 100%
Jul/13
Aug/13
Jul/13
100% 80% 100% 100%
5 •Double click on sheet to edit
Se p/13
Aug/13
100% 80% 100% 100%
Oct /1 3
Se p/13
Nov/1 3
Oct/13
De c/ 13
Nov/13
De c/13
80%
80%
80%
80%
100%
100%
100%
100%
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