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Representative illustration: A global skin-care maker expected major volume from new product launches but had long cycle times and tangled lab dependencies.

Case Study · Consumer Products

A global skin-care maker expected major volume from new product launches but had long cycle times and tangled lab dependencies.

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1Challenge

Manufacturing and the QC, analytical and microbiology labs were tightly interdependent, and growth needed a smooth internal supply chain.

2Approach

  • Built a master production schedule, daily and weekly build schedules and attainment reporting
  • Installed a closed-loop operating system in the pharmacy area and cleared obsolete stock from the warehouse
  • Added lab input/output controls, visual work-order management and weekly capacity models

3Results

27%

Increase in throughput

81%

Increase in inventory turns

26%

Better schedule attainment

50%

Shorter QC lab cycle time

The CEO said the gains let them win new business they had thought was beyond capacity.

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