www.mesa.org2008 North American Plant-to-Enterprise ConferenceSeptember 21-23, Orlando, FL

Manufacturing Science for Lean Manufacturing and Supply Chain

Optimization

Rob Burrows – Pfizer, Senior Director Global Manufacturing Services

Velumani Pillai – Pfizer, Director Global Enterprise Architecture

Dennis Brandl – BR&L Consulting

MSI for Lean Manufacturing and Supply Chain Optimization

The following Strategic Initiatives of MESA International are associated with

this presentation:

Lean ManufacturingProduct Lifecycle Management (PLM)

• Manufacturing science describes the body of scientific knowledge, regulations, and principles involved in the transformation of materials and information into products

• Manufacturing Science Informatics (MSI) defines the information framework used in Manufacturing Science

Manufacturing Science

MSI for Lean and Supply Chain Projects

• The MSI framework contains conceptual models that support all processes that support manufacturing and is based on recognized ISA, IEC, and ISO standards, such as – ISA 88 and ISA 95

• The MSI framework can be easily extended to support of lean manufacturing projects and supply chain optimization projects

Lean Manufacturing

• The essence of lean manufacturing is a focus on the elimination of all non-manufacturing wastes, include:– unneeded inventory– wasted motion– unneeded transportation of materials, equipment, or personnel– quality defects– changeovers

• There is often a main focus on the reduction of three types of waste (using the Japanese terms): – muda (non-value-adding work)– muri (overburden)– mura (unevenness)

The DMAIC Process

• Lean and optimization projects often follow the DMAIC process.

• The basic DMAIC process consists of the following five steps:– Define process improvement goals that are consistent with

customer demands and the enterprise strategy. – Measure key aspects of the current process and collect relevant

data. – Analyze the data to verify cause-and-effect relationships.

Determine what the relationships are, and attempt to ensure thatall factors have been considered.

– Improve or optimize the process based upon data analysis using techniques like Design of Experiments.

– Control to ensure that any deviations from target are corrected before they result in defects.

ProductKnowledgeISA 88.03

ISA 95

ProductionHistory

ISA 88.04ISA 95

ProductionExecutionISA 88.01

DMAIC and MSI Models

Analyze

Define

Measure

Improve

Control

MSI Models

Process Reports

• Process reports define the information that must be collected and reported on during execution of the process– Information used in lean investigations– The most time consuming part of an investigation is

the collection of the process data– Significantly reduce the time and effort required to

perform lean improvement investigations

Criteria for Lean

• What to record:– Transportation time and cost (moving of material that is not

actually required to perform the processing) – Inventory (includes all components, work-in-progress and

finished product not being processed) – Motion (people or equipment moving or walking more than is

required to perform the processing) – Waiting time (waiting for the next production step) – Overproduction (production performed ahead of demand) – Over processing (rework due to poor tool or product design) – Defects (the effort involved in inspecting for and fixing defects)

Standard Lean Manufacturing Process Reports

• Comparisons against industry best practices– These are the best practice values in the same or

similar industries. They provide targets for each site and allow sites to identify areas for improvements.

• Production Time, Waiting Time, Setup/Cleanup Time• Yield• Defects• Waste• Energy Usage• Best Batch Size

Standard Lean Manufacturing Process Reports

• Company best practices– These are the company’s best practices. They

identify which site has the best practice and the values.

– Allows site to site comparison and helps in allocation of capital projects and improvement projects.

• Production Time, Waiting Time, Setup/Cleanup Time• Yield• Defects• Waste• Energy Usage • Best Batch Size

Supply Chain Optimization

• A "lean supply system" will optimize plant and supply chain performance

• Fewer buffers and a segmented approach to managing the supply network and internal manufacturing operations, based on product characteristics (e.g., volume, demand volatility, product value)

Deliver

Enable

Make Source Plan

Alternate Production Processes

• During development of a product or process there may be several alternate production processes defined

Supply Chain Optimization

• Alternate pathways may also be defined in a Site recipe to indicate a modified production method that is suitable within a site– For example there may be differences in local regulations for

emissions or waste production, or alternate methods for disposalor use of byproducts

– Different process may be defined with additional operations, such as cleaning of process streams and recording of waste generated

• Alternate pathways could be defined for different batch sizes– This is especially useful when the chemistry or physics is based

on the surface area of a vessel or container due to reaction of degradation issues

Process Stages for Sourcing Decisions

• Process stages within a general recipe can be used to improve sourcing decisions

• Each stage defines a major transformation and often relates to an inventory point

• This can be used to decide where to produce each stage of a product

Four Sourcing Options from One Recipe

ThioTablets

API Production:1

Tableting:1

Packaging:1

undefined Filtered Water Pentadecanoyl Phthalazinyl

Thiocarbonohydrazide

SaveALot

All Stagesin one facility

Each Stagein different facility

Packagingin separate facility

API productionin separate facility

Alternate Materials

• While alternate materials are often maintained in corporate material master information, not all materials may be equivalent in all processes, so the alternates may be product (or operation) specific

Material Outputs

23379 2000 L Filtered Water8892 20 L Pentadecanoyl99827 3 mg Phthalazinyl99888 40 g Tetramethyl-2-phenylguanidine19645 600 g 3-Ethylcarbazic acid

Material Inputs

88397 540 g SaveALot

5566 600 g Thiocarbonohydrazide88393 10000 tablets ThioTablets88726 2000 8-Blister Packs Thio

Material Intermediates

Materials

Material Alternates

8892 20 L Pentadecanoyl 77627 21.5 L Pentadecanoyl-28892 20 L Pentadecanoyl 77628 19.85 L Pentadecanoyl-3

Summary

• Information for lean manufacturing and supply chain optimization projects can be included in General and Site Recipes and preserved in Batch Production Records– The information could define target values for yields,

production times, setup times, and maximum defects, and could define specific information to be collected at each production facility to be used for global optimization projects

– This information can also be used for sourcing decisions, alternate production pathways, and material selection optimization

www.mesa.org2008 North American Plant-to-Enterprise ConferenceSeptember 21-23, Orlando, FL

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