Process improvement and inventory management using value stream mapping in a biopharmaceutical environment

Abstract

This thesis describes the formulation of short-term and mid-term operational excellence strategies through the use of value stream mapping. It is shown that many interconnected issues form a backdrop for seemingly independent "symptomatic issues" or issues that can be seen readily on the surface because of their significant financial or organizational impacts. These underlying issues indicate organizational improvement projects are necessary in the short term to create an environment conducive to sustaining results stemming from projects addressing the surface issues. One example of a surface issue is that of scheduling where the problem can be readily seen with blockages, starvation, and long cycle times, but must be solved with organizational and other fundamental improvements for improvements to be sustainable. Also presented is a case study showing a root cause and financial analysis relating to the capabilities of the aseptic filling process. The value stream mapping analysis led to recommendations of working on fundamental organizational, communication, and cultural issues to create a strong foundation for improvement projects on more visible projects.