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Novo Nordisk – Design and Launch of An Opex Improvement Programme

Global insulin manufacturer looking for 30% reduction in cost and 25 % increase in output. Executive team convinced that solution was better capacity utilisation and not further capital investment.
  • Identify improvement opportunities
  • Design Opex Roadmap
  • Develop internal Opex and CI skills
  • High level value stream mapping (VSM) of supply chain processes – drove focus
    onto aseptic production, assembly, and packaging
  • Detailed VSM which identified over 100 improvement opportunities
  • Benefit/effort matrix used to focus on 5 critical issues
  • Opex Roadmap developed setting 2 year improvement agenda and Governance
  • Training Programme and Improvement projects Launched
  • Coaching of project leads to ensure benefits delivery and skills transferred
  • Significant production volume increase with no capital
  • Batch record right first time from 48% – 72% -reduced delays
  • OEE increase in bottleneck process(assembly) from 65% -72%
  • Simplified production planning and Kanban replenishment
  • Visual management and ‘lean daily management system’ introduced – rapid response
    to issues
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