Implementation of process optimization to maximize line productivity in pharmaceutical industries

Abstract

Macro Group is the largest player in Egypt’s fast-growing cosmeceutical industry founded in 2002, and Macro has about 149 stock-keeping units (“SKUs”) with a 31.4% market share in 2022. The macro group has three-ampoule products for hair, namely, Atrakta, Verdex, and Solodex with an expected forecast of 134,655 FG in 2023 and it’s expected to reach 261,000 FG in 2027. 188 working days per year in 2023 are required to manufacture the forecasted units and 365 working days to manufacture 2027 forecasted units. Through observing the production line of Atrakta, it has been noticed that the production line could be enhanced to increase the production rate, and hence, meet market demands efficiently. Therefore, this paper aims to study and investigate the Atrakta hair ampoules production line to reach the optimum line productivity and to commit to market needs. Studying the Atrakta hair ampules production line is conducted through interviews, production line observation, data collection, and modeling and simulation of the production line. Two scenarios recommending improvements to the production lines are proposed and simulated. The two scenarios differ mainly in the probability distribution of probabilistic inputs. Simulating the system with the recommended improvements for the two scenarios shows similar results of increased productivity. Simulation results of improved systems show an increase of 300% in daily production from 720 FG per day to 2176 FG per day. According to Atrakta's results, the Macro group decided to implement the same recommended improvements on the similar process of Verdex and Solodex ampoules to reach 2176 FG. The required working days to reach forecasted units in 2023 decreased from 188 to 67 days and also decreased from 365 to 132 days in 2027.ArticleHighlightsThe primary pack items are decreased, and secondary pack of ampoules SKUs has been changed to avoid bottlenecks.The change of primary and secondary pack plays a significant role in increasing the productivity 3 times for the non-sterile ampoules production unit.The increasing of production capacity decreased the required working days in 2023 till 2027.