Value Stream Mapping as a Basis for Process Improvement in the Pharmaceutical Industry

Abstract: Background - The company is a Swedish manufacturer, developer and contract manufacturer of pharmaceuticals. In the last couple of years, the company has entered a growth phase which has led to issues with the internal processes such as material flow, warehouse operations and processes related to the production. The consequence has been occasional issues with delivering the products on time. As a result, the company suspects a need for refining its own processes An issue regarding how to cope with scalability and capacity is also present. The company has therefore expressed an interest in an evaluation of their current state using Value Stream Mapping. The company also wants to know how the value streams and processes can be improved through lean manufacturing techniques. Purpose – This thesis aims to propose improvements to a manufacturing process within the pharmaceutical industry. The purpose is also to evaluate the applicability of Value Stream Mapping as a basis for process optimization in an cGMP (Good Manufacturing Practice) governed environment. Research questions - What deficiencies are affecting the processes and in what way do they affect the business? How can the deficiencies be improved through lean thinking with consideration taken to the contextual limitations given by cGMP? Does Value Stream Mapping constitute a good foundation for process optimization within the pharmaceutical industry? Design/methodology/approach – A single case study was chosen as the research methodology in this thesis. The study was initiated with the setting of the scope and choosing three product families, followed by the construction of three value stream maps. An analysis where waste and other deficiencies were identified was conducted. Lastly, ten improvement proposals were recommended. Findings – This study showed that several deficiencies were affecting the company’s manufacturing process. The waste was also found to be characteristic to the environment given by cGMP. Further, the deficiencies were found to be actionable and in theory approved through lean thinking. Lastly, the study showed that Value Stream Mapping can be used as foundation for process optimization within the pharmaceutical industry.