James Ross Consulting - Nycomed Amersham

Nycomed Amersham

Process Improvement

Client manufactures a range of specialist imaging products for sale world-wide. The product range covers both branded and sub-contract production.

amersham.co.uk

Cell Production

The manufacturing plant produced a variety of different products; these then proliferated by brand, number of vials per pack and language. As a consequence, production run lengths were constantly reducing, significantly impacting efficiency and output. The packing operation and packaging used were based around a single production cell. The operators within this cell were responsible for product inspection, collation and checking of packaging materials, product packing and finished goods inspection. Packaging used was based on a licensed pack format containing a number of glass vials.

Business Challenge

Review and Improve

James Ross Consulting were asked to review the packing area processes, together with packaging formats used, and to define and implement improvements.

How JRC Helped

Integrated Project Team Approach

In order to establish actual product, packaging and regulatory needs we conducted a brief survey of the production and distribution process. This also involved discussions with technical services, regulatory, marketing, QA and QC departments. The survey allowed us to build up a picture of current actual requirements as well as anticipated market / product / brand / co-pack needs.

Proposals for change were then developed and reviewed with the client. Proposals focused around the following key changes: Removal of ancillary processes from the finishing area. Development of more flexible packaging systems (specifically geared to late configuration). Change in layout of the packing cell, to provide a fixed (controllable) output. Changes allowed output to increase over current, dependent upon demand, without significant labour increase. Re-design of the packaging to reduce cost, remove licensed components and standardise finished pack format for all markets. Development of new Materials Handling process to optimize material flow and QA / QC processes. Timing for change was agreed with the client, in line with on-going investment to increase capacity within the manufacturing site. James Ross Consulting were responsible for technical development, trials and costing for all aspects of packaging and plant change.

A Project team was established within the client. This involved representatives from all business functions likely to be impacted by packaging change. A series of trial procedures and costing tools (volume and current cost databases) were developed by JRC and approved by the project team. Packaging and process changes were developed in accordance with these agreed trial / performance requirements. Packaging changes needed to fit with other initiatives within the business. Some elements of the project were implemented ahead of schedule to fit with product / engineering change.

Other aspects required specific market approval in Japan. The project team managed all aspects of equipment purchase and validation. In addition, changes in management structure were required to create a materials management function. JRC carried out packing and distribution trials to define optimum pack configuration and specification. Project involved reviews with line operators to develop optimum pack assembly methods and to communicate benefits of change.Packaging changes, in terms of print consolidation and format were developed with regulatory and marketing. Packaging development was managed in tandem with other planned change to reduce the regulatory burden and origination cost.

Value Delivered

Lean Thinking

Developed new packing process to provide maximum flexibility and response time. Finished packs made to order in production. Streamlined materials handling process for packaging. Reduced actual packaging cost (materials) by circa 80% through creation of generic components. Reduced inventory. Developed new packing process to provide a controllable output for the packing cells. Created packing cell module with moveable equipment to provide flexibility for efficient co-packing / unique products as well as branded items. Cell module layout was based on need to install further cells, in line with planned expansion, within limited available production space. Developed new process for handling and despatch of finished goods, leading to improved service levels and significant shelf life improvement.