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Integration of Active Pharmaceutical Ingredient production into a pharmaceutical Lean Learning Factory

: Petrusch, N.; Sieckmann, F.; Menn, J.P.; Kohl, H.

Fulltext ()

Procedia manufacturing 31 (2019), pp.245-250
ISSN: 2351-9789
Conference on Learning Factories (CLF) <9, 2019, Braunschweig>
Journal Article, Conference Paper, Electronic Publication
Fraunhofer IPK ()

In the context of the implementation of Lean Production Systems, companies have become significantly more aware of the need for employee qualification and motivation. Due to the high share of practice, Learning Factories have proven to be an effective approach to respond to this circumstance. While the focus of Learning Factories has so far mainly been on discrete manufacturing, applications in the pharmaceutical industry are still comparatively rare. Based on this, a Learning Factory, that takes into account the special requirements and needs of the pharmaceutical industry, was developed and implemented in collaboration with a German pharmaceutical company. So far, Lean culture and tools have been trained on formulation and packaging processes. However, the active pharmaceutical ingredient (API) production, which is characterized by a higher level of automation as well as chemical and process engineering procedures, was initially not displayed, as no sufficient demand was assumed. Due to the increasing need for a holistic consideration of the whole value chain, the API production is moving into the focus of Lean improvements. In this context, many established tools need to be adapted. From feedback of over 120 conducted trainings and a series of interviews, it became clear, that for employees from API production, it is difficult to transfer the necessary knowledge to their work environment, leading to resistance in implementing Lean tools. In order to counter this problem, the Learning Factory was expanded by an additional API learning module. This increased the willingness of employees to participate in the trainings and to implement the contents.