API Industrial Engineering Evaluations

Confidential Client Location: Midwest, USA
A producer of Active Pharmaceutical Ingredients (API) wanted a focused industrial engineering evaluation of one of their production buildings. The goal of this project was to identify improvement opportunities and recommend solutions which have the potential to be adopted in other areas of the plant. Processing areas, logistics, inventory locations, operating strategies and information flows were considered in the evaluation. It was required to dollarize the potential savings resulting from the improvement options. 

Bottlenecks and improvement opportunities were identified in various areas of the building. For each improvement opportunity several potential solutions were identified. Value Stream Maps (VSMs) and Discrete Event Simulation (DES) models clearly delineating improvement solutions were developed. The DES model was used to run different 'what-if' scenarios and quantify savings. Cost estimates for each solution were provided.

Client Challenge: Dollarize the savings
"Savings realized from improvement options should be dollarized. Costs (installation, construction and labor) for each option are required to be estimated. This building should serve as a showcase model for future industrial engineering improvements at the plant."

CRB’s Role:
Assessed current operating and logistics conditions to determine improvement opportunities, quantify savings and provide cost estimates for improvement options.

How we helped:
  • Site visits, process and line observation, and data collection
  • Understanding operations, system interactions and information flows
  • Created VSMs and developed DES models for all products made in the building
  • Identified improvement opportunities and quantified savings
  • Provided cost estimates for all recommended options
  • Potential increase in annual revenue of $7.9M
  • Identified improvement options which increase throughput, reduce cycle times and reduce operational inefficiencies
  • Calculated staging space requirements for raw materials, intermediates and finished goods
  • Recommended several new project opportunities to their internal teams
  • Presented results and analysis to their site leadership team
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