A

PRESENTATION ON THE
STUDY OF LEAN MANUFACTURING SYSTEMS AND APPLICATION
OF LEAN MANUFACTURING PRINCIPLES AT CUREX
PHARMACEUTICALS
THIRD YEAR PROJECT
PROJECT MEMBERS
SABIN LAMICHHANE(32083)
KRISHNA PRAKASH UPADHYAY(08088)

OUTLINES:
Introduction
Objective
Literature Survey
Company Overview
Methodology

Problem Discovered During Research

Suggestions
Works completed
Problems Encountered
Plant layout
Flow chart
Process study
Analysis of wastes
Gantt chart
Cost Estimation
Conclusion
References

INTRODUCTIO
N
Study of manufacturing systems,and lean manufacturing

principles.
Different kinds of wastes produced in the industry
advantageous if those wastes can be identified and reduced
carried out in two phases
first phase, critically observed the manufacturing processes
second phase, derived solutions and suggest for
improvements .
talks about optimizing and eliminating wastes.
Helps to reduce the interruption of production process
Latest technology used on almost all industries to from
small workshop to industries that built boeing 757
believes in continuous and steady improvement

OBJECTIVE
S
To study the manufacturing process in industry.
To observe the application of lean manufacturing

principles and solve existing problems

implementation of solutions to reduce non-value
adding wastes.
To gain knowledge of industrial management
systems.
To build our professional attitudes.

LITERATURE SURVEY

Waste is anything that does not add value to the product.

The reduction of wastes is important
Every types of wastes are interconnected
Types of wastes:

Overproduction
Movement
Inventory
Storage space
Repair and rework
Transport
Waiting time

LEAN TOOLS
SINGLE MINUTE EXCHANGE OF DIE(SMED)
Practice of reducing the time to change the
die from one product to the next
It doesnot tell to change die within a minute
but not more than ten minutes
concept is first introduced by the engineer
Shigeo Shingo of Toyota company

5s process

Powerful lean tools comprises of five Japanese words

Seiri, Seiton, Seiso, Seiketsu, and Shitsuke

Its English equivalent are Sort, Set, Shine, Standardise and

Sustain.

Seiri- refers to the act of throwing away all unwanted,

unnecessary, and unrelated materials from the workplace

Siton- talks about the efficiency in the workplace. It is

achieved through putting everything in an assigned place
so that it can be accessed or retrieved quickly

CONTD..
Seiso- talks about the maintenance of the

machinery
within a industry
suggest all the workers to be a caretaker
Seiketsu- English translation is Standardise
maintain standard through cleanliness of
both personal and environment
Shitsuke- It means discipline in English.
denotes commitment to maintain orderliness

KANBAN

concept related to Just in time(JIT)

a scheduling system that helps determine

what to produce, when to produce it, and how

much to produce
Concept is used when demand is fluctuating
and forecasting is very difficult
Uses kanban card that signals the depletion of
product part or inventory levels in the
production area

TOTAL PRODUCTION SYSTEM(TPM)

a maintenance philosophy designed to

integrate equipment maintenance in the

manufacturing processes
TPM emerges out since Maintenance of the
machine should be done in minimum time
Suggests to form the team which evaluate the
Availability, Performance and Quality of the
machine parts

Kaizen
highly focused improvement events designed to

address and resolve important business issues or

constraints.
critically evaluate and scrutinize to discover
where opportunities for improvement exist.
We find real solutions and begin implementing
the needed changes immediately.
team effort best engaged in by associates from
the area of focus, supporting areas, and internal
customers.
substantial improvements have been made, plans
and responsibilities for longer range
improvements.

Heijunka
system for advanced scheduling of production

activities.
allows to reduce inventory, decrease leadtimes, and produce the variety of products
generalizes the application of tool across
product lines, factories, and the entire
enterprise.
implement time depends on the complexity
of our needs

Lead
time
Reduction

Reducing inventory will decrease our leadtime.

Excess inventory is a great waste, quality
issues (spoilage), storage requirements,
investment of funds,
When beginning this process we must know
the status of inventory levels.
categorize inventory and new acceptable
inventory levels are established as goals.
Careful consideration of cost, space
requirements play an important role in
determining reduced inventory levels.

PROBLEM DISCOVERED DURING

RESEARCH
Lack of effective interaction between the company

management and lower level staffs so that many

problems generates
Loss is more due to the wastes of tablet foils labels
etc used in the packaging sections
Maintenance department has three staffs which is
less as compared to the machinery in the company
Have to brought technician from India which
interrupt in the production for very long time.
Store- store is designed under traditional way so
its difficult to find the required materials

CONTD.
Loss due to the wrong forecasting
Interruption of production when there is a

shift change
Interruption of production when changing the
die

SUGGESTIONS
Company should conduct a workshop to minimize the

communication gap between the management and the

lower levels staffs
Workers in the Packaging sections should concentrate more
on their works
Company should conduct the training to the workers
Increase the number of staffs in the maintenance
department .
Workers of the next shift to come little earlier about half an
hour so that they can prepare themselves with their
required tools
It would be better if automatic system is used to change
the die.

ADVANTAGE OF LEAN
MANUFACURING

Benefits are cost reduction, lead- time

reduction etc.
Reduced work in progress(WIP) up to 80%
Floor space savings around 30%
Increased productivity at least by 30%.
Quality improvement by a factor of two.
Overall cost reduction.
http://www.toyotageorgetown.com/history.
asp

Secrets of Toyota

One of the best automobile Japanese

companies,

caught the worlds attention in 1980s which

was special about its quality and efficiency.

Toyotas performance has left other automobile

companies far behind it.

excellence is based in part on tools and quality

improvement methods made famous by Toyota

introduces the techniques like kaizen, one

piece flow, jidoka and heijunka.

14 major principles behind the Toyotas

success
`

A 4p Model of the Toyota Way

IV. Continuously Solving Root Problems
Drives Organisational Learning

Problem
Solving
People and
Partners
Process

Philosophy

III. Add Value to the

Organisation by Developing
Your People and

II. The Right Process

will produce the Righ
Results
I. LongTerm
Philosophy

COMPANY OVERVIEW
Curex Pharmaceutical Pvt. Ltd
Established in 1992 under entrepreneurship of Mr.

Pawan Mittal
entered into the market in 1993 with its quality
products
products have grown high because of companys
strong infrastructures, well equipped manufacturing,
quality control
philosophy is quality should be built into the product
and not merely tested in the finished product.
slogan is Zero defects at all levels.

METHODOLOGY

Defining the objectives of the project

Selecting the industry which can be

beneficial for our project

Visiting the sites to study the problems
exists in the company
Using lean manufacturing principles in
the company
Finding the solution for the problems
based on the lean manufacturing tools.
Informing the company about the
problems and solutions obtained during
our research project.

Works completed

Literature Review
Overall plant visit of Curex pharmaceutical.
Collection of data and information from the

manufacturing line.
Learn to identify the problems exists in the
industry
Discuss existing problems with industry
supervisor
Design the plant layout and process flow
chart
Provide the solutions of the existing problem
of the Curex Pharmaceutical company.
Provide suggestion and verification

Problems
Encountered
Industrial identification
Difficult to find the companys in charge

for getting approval

Difficult to get the time of companys
staff.
Difficulty on visiting industry.
Very selective time
Feels very difficult to implement the
suggestions given

PLANT LAYOUT

ALL DIMENSIONS ARE IN FEET

PRODUCTION FLOW CHART(TABLET SECTION)

FLOW CHART OF LIQUID PROCESS

PROCESS STUDY
Process
level

Practical/
real time

Optimum
time

Causes

Way of
material
handling

Stock level

Delay
process

Wastes in
manpower

Wastes in
materials

Wastes in
places
/storage
area

Dispensing

Depending in
batch size1-2
hrs.

Nearly same

Continuous
process

manual

low

Mostly
Nearly 1
delayed due
to lack of line
clearance

Contaminatio
n chance

Yes

Transportatio
n

15 min

1-2 min

manual

High

No use of
conveyor belt

1-2

Sieving

30-60 min

Nearly same

Delay in
material
handling
Continuous
process

Vibro sifter

Continuous

No

Loss due to
spillage

No

Mixing /
Granulating

30 min

Nearly same

RMG

Continuous

No

Due to
sticking

No

Paste
preparation

1-2 hrs

30 min(ice
bath)

Due to time
on cooling

Paste mixer

No

Due to
worker
handling
Due to
worker
handling
Due to
cooling

1-2

Required not
fulfilled

No

Drying

1-6 hrs

Same

Due to fixed
time process

FBD

No

Lack of
moisture
testing
apparatus

1-2

Due to
spillage

Transportatio
n

15-20 min

5 min

Lack of
conveyor belt

Manually

No

Manual
work

1-2

Lubrication

40 min

20-30 min

Manually

No

1-2

Compression

Depending
on
formulating

same

Not setting of
formulation

Octagon
blender
Compression
machine

yes

Setting of
machine
+formulation
process

No

High

No
Due to
spillage
Due to trial
and spillage

No
Yes

ANALYSIS OF WASTES
Wastes

Instances

Overproduction

Dispensing
compression

Movement

Dispensing
granulating

Inventory

Dispensing,
Compression

Storage space
Repair
Rework

Causes

Solutions/

, Long setups on these machines, more supply of Improve setup times of machines to produce
materials than we actually needed,
smaller batches, Use ideas of JIT
manufacturing to enable the production at
needed, enable pull of production .
,mixing, Cell layout, placing products at floor level on pallets,
poorly arranged space, machines that are
disorganized, etc.
Lack of knowledge in worker,
increasing work time hour

Providing knowledge on workers on 5S, it

helps to review each and every steps of their
operation, improving cell layout and machines
set-up.

Delayed due to line clearance+ setting of machines Reduce overproduction, use idea of just in
formulation, overproduction, poor layout lack of time, Kanban can be used to balance in
balance workflow making inventory in before or after between the processes
different processes.

Dispensing,
Line clearance
Reduction in overproduction, inventory,
compression
reduces storage space.
and Mixing,
paste
Unclear standards and specifications, Due to Ice bath for paste preparation, Standardization
preparation, drying, machine disorder, Settings of machine accordingly.
of the methods,
Timely checking of
compression, blister
machines,
packing

Transport

Between dispensing Overproduction, inventory, due to factory layout,

Reduce overproduction ,inventory, reduce
and sieving , paste excessive gap between operations, multiple storage processes distance as far as possible,
preparation
and location.
Conveyor belt , efficient factory layout
drying,
drying,
compression

Waiting time

Paste preparation , Lack of cooling, moisture testing apparatus, setting of Adding machines like intercooler, balancing
compression, Drying , machines, unbalanced processes , overproduction production
processes,
reducing
Blister packaging
inventory, delay in material handling processes,
overproduction and inventory to minimize
transport between processes, use of effective
transportation within cells

CHART
Team & Project
Selection

Work
Accomplished

Proposal
Submission

Work Remaining

Literature
review
Industrial
visit\Critical
observation
Simulation & Value
streamMapping

Implementatio
n of lean tools
and techniques

Analysis of wastes
and solutions

Verification of our
suggestion
Month/Year

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

July

Aug

Sep


COST ESTIMATION

S.
No.

Materials

Quantity

Rate (R.s.)

Total(R.s)

1.

Books

600

2400

2.

Software

3.

Transportation

(3*10)+(2*10)

15

750

Grand Total

Total cost of our project is estimated to be R.S.

3150

3150

CONCLUSION
Based on lean manufacturing principle
Application in increasing production
able to know the technology and production process of an industry.
good opportunity to know, understand and achieve the practical

knowledge.
found out the different hidden wastes that exist in the
manufacturing processes which were not considered and noticed.
We have found the possible solutions that can be implemented for
improving the quality and reducing the production cost.
learned to develop the professional attitudes towards the company.
also expected to be beneficial for the industry.
Great support from Curex staffs and supervisors

REFERENCES
Jeffrey k. Liker, The Toyota Way ,17th ed.,

Tata M.c. Graw Hill, 2007

Mike Rother & John Shook, Learning To See,
Version 1.2,Lean enterprise institute,1991
http://www.toyotageorgetown.com/history.asp

THANK YOU