Lean Plant and Shop Floor Integration Process Automation

A major pharmaceutical manufacturer was undertaking a Lean program to institutionalize Lean supply chain and plant performance metrics. They had a number of performance metrics systems and manual processes in place. Labor efforts to ensure consistent definition and calculation of KPI's required additional staff or increasing work load on existing staff.

The client had a program team made up of key personnel from manufacturing, supply chain, packaging, QA, and plant leadership. The client had the necessary staff to participate in a project but lacked the project and technical skills to carry out the project in the required timeframe efficiently.

Endeavor was retained to rapidly deploy SAP's MII tool to help reduce the labor effort to calculate supply chain and plant performance metrics. Endeavor's approach was to leverage all the work of their existing Lean program (definitions and business processes for calculating KPI's) and implement SAP's MII to produce both management and supervisory KPI Dashboards. We provided the project management, and technical staff to integrate data sources from ERP, shop floor, OEE, and QA systems.

Cross trained company technical staff in SAP MII enabling them to be self sufficient in the future. Endeavor designed and implemented solutions that could be leverage by other facilities and departments. Produced a program approach and plan designed to ensure business and integration benefits were realized. The client was able to roll out a system that required minimal labor to maintain and produced real-time KPI dashboards on demand in real-time.