Enhancing Operational Efficiency in Manufacturing with OSICS
This case study highlights the testimonial of Alain Prolong, a consultant who completed a six-month assignment with a client of OSICS. Alain played a pivotal role in transforming the client’s operational processes, focusing on new ways of working, enhancing performance management, and preparing for the launch of new commercial activities.
Our approach, combining technical expertise and cross-functional collaboration, not only resolved longstanding logistical issues but also laid the groundwork for proactive and efficient supply chain management in the pharmaceutical industry.
Initial Challenges
When Alain first joined the organization, the client faced several operational challenges. One of the most critical aspects was understanding the organization’s workflow and identifying gaps. Alain quickly realized the importance of:
- Building connections with employees across various departments.
- Engaging directly with the shop floor to understand the root causes of issues.
- Delving into operational details to uncover inefficiencies and undocumented practices.
Approach
“Go See and Understand” Principle
Alain adopted a hands-on approach inspired by the Toyota Production System’s principle of “Go See and Understand.” This meant regularly visiting the shop floor and laboratories to:
- Observe operations firsthand.
- Build trust and establish relationships with team members.
- Identify inefficiencies and areas for improvement.
Building Connections
Initially, many employees were reserved and hesitant to share information. To overcome this, Alain focused on:
- Breaking the ice by being present and approachable.
- Becoming a familiar face, which helped gain access to critical tacit knowledge that wasn’t documented in standard operating procedures (SOPs) or batch records.
Training and Integration
Extensive Training Requirements
Alain underwent comprehensive training to gain access to controlled environments. This included:
- Completing SOP training and qualifying for facility access.
- Gaining a deep understanding of manufacturing processes to align with the company’s operational needs.
Integration into the Team
Alain emphasized the importance of becoming an integral part of the organization by:
- Building relationships across all levels of the company.
- Gaining trust to effectively address and resolve issues.
Performance Management Improvements
Enhanced Performance Boards
One of Alain’s significant contributions was the improvement of performance management boards. These enhancements enabled:
- Better tracking of progress and planning of activities.
- Reduced risks by increasing visibility and redundancy across teams.
Shift Handover Plans
Alain introduced a new shift handover process in the production zone. This allowed:
- The outgoing shift to document progress and set up tasks for the incoming shift.
- Improved planning and coordination, reducing the risk of tasks being overlooked.
Operational Excellence Board
Outside the controlled environment, Alain revamped the operational excellence board, which provided a clear framework for:
- Tracking deviations and manufacturing progress.
- Offering a comprehensive overview of the facility’s operational status.
Impact and Resilience
Fabrice summarized the overall impact of Alain’s work, highlighting their:
- Resilience and experience, which helped the organization overcome significant operational roadblocks.
- Hands-on approach that fostered a culture of continuous improvement and proactive problem-solving.
Key Follow-Up Actions
- Shift Handover Process
Alain will continue to implement and refine the shift handover plans to enhance planning and minimize redundancies in the production zone. - Operational Excellence Board
The operational excellence board will be further developed to provide even more detailed insights into manufacturing progress and performance. - Change Notification Management
Alain will maintain oversight of complex vendor change notifications to ensure timely and effective resolution, reducing potential risks to the production process.
Conclusion
Alain’s contribution during their six-month assignment was transformative, providing the client with improved operational efficiency, better risk management, and a more resilient approach to managing changes. Their dedication and expertise helped the organization prepare for future commercial activities while fostering a culture of continuous improvement.