Application of VSM for process improvement in the pharmaceutical industry

Abstract

To further our understanding of lean manufacturing principles in complex environments, this research aimed to describe and explain how the application of Value Stream Mapping (VSM) enhances process improvement in the pharmaceutical industry. Through a case study methodology, this research examines the process of identifying the value stream, creating the current state of VSM based on observations during Gemba walks, Ohno’s cycles and secondary organizational information, waste identification in the process, and designing future state of VSM. The findings showed that VSM applied in combination with other lean tools such as 5S and 5W not only enhances waste identification and its elimination from the process, but also enhances lean information management, reaching basic stability, emphasizes the importance of visual management, change management and lean readiness. Ultimately, the findings suggest that the application of VSM for process improvement ensures efficient and effective value identification, waste exposure, process optimization, and most importantly, ensures sustaining the improved process, facilitates continuous improvement, which allows to reduce lead times, improve operational efficiency, and thus, enhance speed to market and make operational excellence a competitive advantage.