Configuration of an electronic Kanban board for planning analysis activities at an industrial laboratory

Abstract: To improve productivity, it is important that the right product is produced in the right quantity when that product is needed. Kanban is a way to signalise the need for material and its main aspect is that it pulls materials through the processes only when needed. Kanban can therefore help reduce Work In Progress (WIP). Quality Control (QC) at AstraZeneca in Södertälje is tasked with controlling the quality of batch samples from production. Several different analyses need to be performed on a batch and all the analyses should preferably be done at the same time to reduce the levels of ongoing work. The currently used system and working procedures for planning analysis activities at the QC laboratories results in high levels of WIP. The aim of this project was to investigate the possibility to replace the currently used planning system with an electronic Kanban board so that WIP can be limited and a more predictable flow achieved. Observations and discussions have been conducted to understand the current state of the QC process. A literature review has been conducted to form a theoretical framework for concepts such as Just-In-Time and Kanban. A Kanban board has been configured using a software suggested by AstraZeneca for one team. The functionality of the board is presented along with a discussion of how it can be used in their operations. It has been configured so it is possible to prioritise the completion of ongoing batch analyses before new batches are started, making it possible to reduce WIP and achieve a more predictable flow. Tasks are to be prioritised according to a decision tree. Limitations in the construction of the board and challenges with a potential future implementation are discussed. The board has been presented to team leaders and analysts to gain their input. Based on this, some alterations have been suggested. A suggestion for the setup of a pilot test is presented. It is recommended that the board is tested in parallel with the current planning system to evaluate the possibility to implement the board in a larger scale and to further investigate challenges and possibilities with the software.