Lean and agile practices to improve the performance of filling process via simulation and data envelopment analysis

Abstract

This research aims at identifying the appropriate lean and/or agile practice(s) to improve the performance of filling process in a pharmaceutical industry. Initially, the As-Is simulation model of production processes was built and then run to estimate the process’s output measures; averages of input bottle, work in process, waiting time, cycle time, and output bottles. The simulation results showed overall equipment effectiveness (OEE) score for some production processes were smaller than the recommended minimum world-class values. Consequently, agile and/or lean practices were utilized to generate nine To-Be improvement scenarios. Simulation was run to evaluate the process’s output measures and OEE score for each scenario. Finally, the slack based model (SBM) in data envelopment analysis was adopted to determine the best improvement alternative. The SBM results revealed that the lean practice “adding another head to the labeler machine” is the best alternative that may result in anticipated improvement in the OEE by 13.5%. In conclusion, the lean and/or agile practices can result in significant savings in production and quality costs.