"Super-Charging" Lean Kaizen Events with Rapid Action Teams
Performance Snapshot Preview: A large production site for a global bio-pharma company engaged a fleet of employee-led, just-in-time teams to speed up implementation of a Kaizen Event-inspired new production process, resulting in a doubling of output and more than $2.25M saved in better production yield in just over 60 days.
SituationA large production site for a global bio-pharma company needed to dramatically increase product through-put and yield within a key stage of its production process for a core product line.
Team Engagement StrategyA weeklong Kaizen Event to value-stream the production process was facilitated by an expert Lean Six Sigma Black Belt and supported by an immediate launch of three frontline employee teams who used Rapid Action, an "all in one" team engagement toolkit for accelerating results, to fully implement the new process design with minimal disruption of current operations.
Rapid Action Project CharterHow can we implement the new Stage I production process in order to achieve targeted levels of production through-put and yield with minimal disruption to current operations?
Sample of Solutions Implemented
- Completed a complete 5S site clean-up and reorganization protocol.
- Designed and installed standard set-up kits to prep production lines and minimize opportunities for error.
- Implemented a kan-ban system for replenishing the line with all supplies and raw materials.
- Developed a staging and delivery system for equipment using a smooth-flow model for the fermentation unit, removing more than two miles of excess transportation.
Rapid Action Team Results
35solutions tested and implemented by three teams
100%improvement in through-put within 60 days
80%reduction in product losses
64 dayscycle time from team launch to wrap-up
"We've used Kaizen Events in the past to “lean-out’’ our processes, but we always struggled with completing implementation of solutions. I was amazed at what we accomplished using Rapid Action to unleash our frontline operators in the improvement effort." – Fermentation Process Director
Learn more about the Rapid Action Toolkit
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