OpEx at Nycomed Austria Linz

OpEx at Nycomed Austria Linz

OpEx KPIs People (current status): 221 Yellow Belts (Target 2011: 291) 3 Green Belts 3 Black Belts Projects OPEX Activities Pipeline 2 About to be started 1 Ongoing 16 Completed 0 0 10 20 30 40 0 60 # M. Schwarzenbacher Nycomed Austria GmbH Slide 2

OpEx supports Nycomed Strategy Product Availability Competitive Costs Right Quality Resolving of a bottle necks for a strategic products Yield increase reduction of unit costs Postponing of capacity increase Support of inventory reduction Reduction of product variation Reduction of deviations due to yield below minimum M. Schwarzenbacher Nycomed Austria GmbH Slide 3

OpEx initiatives at Nycomed Austria Understanding and improving processes Wave 1 Wave 2 Wave 3 Value Stream Actovegin Value Stream TachoSil Value Stream Pharmaproduction Start: September 2008 Start: March 2009 Continuous Improvement! Start: January 2010 M. Schwarzenbacher Nycomed Austria GmbH Slide 4

Wave 1 Value Stream Example Supplier Information Control Efficient Planning (Pull)? 18 Months Forecast 3 Months fix plan Customer Bi-weekly Schedule Daily Schedule Daily Schedule Blood Source Optimization (Process Flow, Yield, Effect on Filters, etc.? Campaign Size? 3 months 1.4 Deviations per month 12 weeks Raw Reduce Deviation Processing Time (current average: 37 days)? Shift (Charges) Model? Filtering Process Optimization? Total C/T = 20 hours Defect = 10% Uptime = 93% 1.4 Deviations per month Yield Improvement (blood source)? Cleaning Time? 20 hrs. Reduce efforts in QC documentation processes (waste reduction, preparation for a LIMS) Inventories (Work in Progress Stages, Finished Product? 3 weeks 3 weeks Primary Total C/T = 11 hours Defect = 2% 1 Shifts Uptime = 4% 0.2 Deviations per month Additional deviations in Biologic Production: 2.6 Deviations per month 11 hrs. Quarantine times? 3 weeks 3 weeks Reduce # of Deviations? Intermediate Total C/T = 19 hours Defect = 2% Uptime = 7% 0.4 Deviations per month Process Time Reduction? 19 hrs. 6 weeks 6 weeks 6 weeks Bi-weekly Schedule Total C/T = 7 hours Defect = 1% 1 Shifts Uptime = 4% Dragees WSG Total C/T = 6 hours Defect = 1% 1 Shifts Uptime = 4% 0.2 Deviations per month 7 hrs. Combine Process Steps? 2 days 3 weeks weeks Granulate 2 Mix Ampoules 3 Shifts Availability: 74% Other products Total C/T =. hrs. Defect = 3% Uptime = 8% Online Printing of Ampoules? Filling Line 1 Change Over Time? Downtime? Clean & Fill 4 3 Shifts C/O = 1.39 hours Uptime = 8% Availability: 74% 2.2 Deviations per month Quarantine Procedure? Quarantine & Chemical Tests Total C/T = 2 days 3% of batches to go thru 1 additional 2 weeks, 0.% thru 2 additional 2 weeks (in 2007). Sterile Test Total C/T = 10 days. hrs. 400 hrs. Change Over Time? Inspect 2 3 Shifts C/O = 1.26 hours Uptime = 69% Availability: 44% 1. days 0.3 weeks Marchesini Package 3 3 Shifts C/O = 0.74 hours Uptime = 72% Availability: 73% Package C/O = 1.2 hours Uptime = 100% Availability: 62% Interface Warehouse, Repackaging? Product Release Total C/T = 2. days 1 Shifts King Line Product Release Total C/T = 37. days 1 Shifts 600 hrs. Lead Time = 42.6 weeks Processing Time = 1063 hrs. M. Schwarzenbacher Nycomed Austria GmbH Slide

Project Selection Supplier Blutbeschaffungsstrategie effiziente Abwicklung der Kundenaufträge Mix Clean & Fill Quaratine & chemical tests Verkürzung Quarantänezeit Inspect Customer Evaluierung Transportgebinde Package Product Release wiederkehrende Abweichungen; Keimzahl verd. Blut 3 months Raw Primary Intermediate 6 weeks Outputerhöhung Zwischenkonzentrat 2 days Other products 4 2 1. days Optimierung Rüstzeiten Reduzierung Sterilabfüllung & Sichtung Bearbeitungszeit Verpackung Dokumentationszeiten PPA Produktion Sterile Test 3 Reduzierung DLZ Freigabe 3 weeks 3 weeks QK Freigabe in Zwischenstufen 6 weeks Dragees WSG Granulate Package Product Release 3 weeks 2 Reduktion der DLZ von Abweichungen; Bestandskonzept Supply Chain; Verkürzung Prozesszeit für Ersatzteilbeschaffung M. Schwarzenbacher Nycomed Austria GmbH Slide 6

ACCESS strikes back

Presenter Nycomed October 2009 Internal Use Only

Portfoliomanagement in i-nexus

Projektmanagement in i-nexus

OpEx initiatives at Nycomed Austria Understanding and improving processes Wave 1 Wave 2 Wave 3 Value Stream Actovegin Value Stream TachoSil Value Stream Pharmaproduction Start: September 2008 Start: March 2009 Continuous Improvement! Start: January 2010 M. Schwarzenbacher Nycomed Austria GmbH Slide 14

KVP Was wird NEU? Ideeneinreichung/Priorisierung/Umsetzungsentscheidung findet in der Linie statt Ideencoaches JEDER kann Ideen einreichen Anerkennungsprämie für Ideeneinreichung & für Umsetzung Einmalige Prämierung (kein Mehrjahresnutzen mehr) Dienstpflichtregelung: nur mehr JA/NEIN-Entscheidungen M. Schwarzenbacher Nycomed Austria GmbH Slide 1

Idea-Management in i-nexus

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