Increasing the Stability of Production Processes: MERCK Case
Discomfort: Customers were unhappy with the Lead Times and Effectiveness in the following processes:
• Production Flow Stability
• Ineffectual Maintenance Processes
• Ineffectual Maintenance Processes
o Service requests left unanswered or fulfilled tardily
o Low rates of problem resolution
o Low productivity of the available specialized workers
o Low rates of problem resolution
o Low productivity of the available specialized workers
Engineering Projects:
• Sluggish processes because of red tape
• Excessively long response times
• Excessively long response times
Global Technical Operations (GTO)
• Introduction of new, highly complex processes and products
• Processes for technical improvements take much too long
• Processes for technical improvements take much too long
Preparation of a Current State Map:
Root-cause analysis of waste generation
Preparation of a Future State Map with the purpose of:
• Reducing lead times
• Eliminating wastes (unnecessary steps, rework activities, waiting times)
• Higher process effectiveness
• Eliminating wastes (unnecessary steps, rework activities, waiting times)
• Higher process effectiveness
o Control of available specialized workers
o Less Time to Respond to Users
o Less Time to Respond to Users
Gains:
• Reduction of lead times
• Elimination of wastes (unnecessary steps, rework activities, waiting times)
• More Effectiveness:
• Elimination of wastes (unnecessary steps, rework activities, waiting times)
• More Effectiveness:
o Control of the Available Labor Force
o Less Time to Respond to Users
o Less Time to Respond to Users