Problem Statement

API manufacturer had an issue with higher cost and lower productivity in one of the products. Despite having data maintained under GMP, team was struggling to find out optimum settings through data analytics

Approach by Minton

• Minton’s executed operational excellence project and made two workstreams one for cost optimization and one for productivity
• Thorough analysis and with the help of in house subject matter experts we could able to identify various levers to reduce utility cost, MRO cost and manpower optimization. Statistical analysis tools used to find out parameters for yield improvement
• As is process mapping was done using Lean levers to find out bottleneck and potential solutions for productivity improvement
• Project was executed for 10 months to implement solutions to achieve the desired results
• Redesigning of processes and systems, implemented low cost automation to achieve lower cost and higher productivity. Team was also trained on statistical analytic tools and Lean practices

The Results

Annual utility cost saving INR 3.5 Cr

Yield improvement for a particular product ~ 2%

Cycle Time reduction for 2 products – 6 hours, resulted in 4 extra batches per month