Our manufacturing client aimed to decrease manual entries by 20% while ensuring the successful validation of the consent decree.
Enhancing the Cleaning Documentation Process
Client challenge
The cleaning process for a Fortune 50 pharmaceutical company under a consent decree involved a complex workflow, causing frequent delays, errors, and mistakes. Cleaning documentation records across multiple plants required as many as 1,500 manual fields, contributing to a low first-pass yield of 44%. This inefficiency resulted in delays in product shipments.
Our solution
The cleaning process involved excessive handoffs, approvals, unnecessary steps, and long wait times. The absence of automation also led to excessive rework. We eliminated non-value-added activities and streamlined the cleaning procedures to cut redundancy and clarify the language. As a result, we reduced manual entries in cleaning records by eliminating unnecessary checkboxes and signatures. Additionally, we established operational metrics and reporting for improved efficiency.
Results
Manual entries decreased by 33%, and weekly cleaning hours were cut by 21%. Additionally, we saved over 2,300 hours annually in approvals. The total cost savings from this engagement amounted to $755,000 annually.
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