Spotlight: Is batch variability affecting your pharma compliance? Checkout how Kaizen transformed chaos into compliance and consistency, driving down batch deviations by 40% in pharma manufacturing.

This post details how targeted Kaizen initiatives significantly reduced deviations, boosted regulatory compliance, improved SOP adherence, and built stronger collaboration between production and QA teams in a mid-sized SE Asian pharma company.

Consistency and compliance aren’t automatic—but Kaizen makes them achievable!

Ready to enhance your compliance and operational consistency? Start your Kaizen journey today— read full case study below...

How Kaizen Boosted Stability, Compliance and Reduced Batch Deviations in Pharma Manufacturing: Case Study

The Challenge: Tackling Variability and Compliance Risks
In pharmaceutical manufacturing, variability and compliance risks can be devastating. This case study is about how a mid-sized SE Asian pharma company successfully implemented Kaizen to sort out its compliance issues and audit vulnerability which adversely impacted its productivity, operational cost and customer trust.

Root cause analysis showed that each shift performed procedures slightly differently, multiplying errors and inefficiencies. Batch variability, deviation spikes, and operator-driven inconsistencies were creating compliance risks and eroding customer confidence. Quality events, rework, batch delays and rejects were adding cost and risk. Process variation was showing up in the metrics—and the market.

The Kaizen Solution: Cultivating Stability and Compliance through Continual Improvement
Kaizen’s power lies in its emphasis on continual, incremental improvements that build sustainable compliance and operational stability. Our initiatives focused squarely on:

• Reducing Human Error: Specialized teams tackled variability by standardizing critical procedures, enhancing compliance.
• Gemba Walks, Layered Audits & Coaching: Regular gemba walks and audits reinforced adherence to Standard Operating Procedures (SOPs), boosting compliance across operations.
• Quick Wins: Short-term successes were leveraged to drive long-term cultural adoption of continuous compliance improvement.

Implementing the Fix:

• Cross-Shift Alignment: Kaizen events aligned shifts on compliance-driven best practices.
• Visual SOPs & Mistake-Proofing: Clear visual instructions and error-proofing at critical points significantly reduced operator errors, improving compliance.
• Proactive Daily Huddles: Daily team discussions emphasized deviation prevention, embedding proactive compliance into daily operations.

The Results: Transformative Stability and Compliance

• 40% drop in batch deviations, enhanced operational reliability and regulatory compliance. Faster batch release.
• SOP adherence up across all shifts.
• Improved audit readiness and regulatory confidence.
• Stronger collaboration between production and QA. Predictable performance across lines and shifts. Operators owning quality; fostering a culture of continuous regulatory excellence.

​Key Takeaway: Compliance Equals Trust
In pharma manufacturing, consistency and compliance aren’t just operational metrics—they're the foundation of regulatory success and customer trust. Kaizen brings teams together to fine-tune the details that matter most.

Kaizen doesn’t just address immediate problems—it transforms the operational culture, embedding sustainable, repeatable compliance excellence into daily practices. And, process consistency isn’t automatic—but Kaizen makes it achievable, repeatable, and scalable.
​
Kaizen isn’t just about fixing problems—it’s about embedding consistency and capability into your operations.
Ready to enhance your compliance and operational consistency? Start your Kaizen journey today…

More Operational Excellence Case Studies at: https://www.drshrutibhat.com/blog/category/case-studies

Keywords and Tags:
#Kaizen #PharmaManufacturing #OperationalExcellence #QualityCulture #ContinuousImprovement #ProcessStability #LeanPharma #PharmaLeadership #SitePerformance #LeanStrategy #ProcessReliability #QualityExcellence #LeanInPharma #GMPCulture #KaizenOnTheFloor #BatchReliability #OpsExcellence #ComplianceExcellence
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Categories:  Operational Excellence Case Studies | Life Science Industry | Kaizen 

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The recent report of gas leak at a chemical factory in Thane, India, resulting in residents complain of eye irritation and breathing difficulties, serves as a critical reminder of the importance of operational excellence in ensuring safety and crisis management. (Ref. https://timesofindia.indiatimes.com/city/thane/gas-leak-at-chemical-factory-at-thanes-ambarnath/articleshow/113302693.cms and https://www.businessinsider.in/india/news/gas-leak-at-chemical-factory-in-thane-locals-complain-of-breathing-difficulties/articleshow/113311787.cms ).

Disclaimer: This is not to comment in any which way about the incident as I do not have an official statement neither from the company nor concerned authorities. But as an Operational Excellent Expert, I am giving my perspective and insights about how any company can embrace proactive safety management to prevent/ manage such crisis.

Although I am writing this blogpost because I read those newspaper articles, such an untoward incident can happen anywhere, in any part of the world and to any company, not just with chemical manufacturing units. Safety to employees, community and the business is not an option, it is a default requirement. Therefore, I believe, some of the insights mentioned here can be made use of, by any business sector.

Having said that, here are main four areas chemical manufacturing companies must focus on:

1. Prioritize Safety Through Rigorous Risk Management
Operational excellence strategy roadmap of a chemical industry must prioritize safety as its foundation. This incident underscores the need for a comprehensive risk management framework, where potential hazards must be identified, assessed, and mitigated through proactive measures. Conducting regular audits, real-time monitoring, predictive maintenance of equipment and the facility at large, can prevent such leaks before they occur.

2. Implement Advanced Safety Technology
Chemical plants must leverage advanced technologies to prevent safety incidents like gas leaks. Install IoT-enabled sensors, AI-driven predictive analytics, and automated shutdown systems, as they can detect irregularities in gas emissions and automatically initiate containment measures. Such technologies also allow for rapid response, minimizing harm to employees and nearby residents.

3. Crisis Preparedness and Immediate Response
When a crisis occurs, response speed is critical. A well-established crisis management plan, backed by continuous staff training and simulations, ensures employees and local authorities can act swiftly. Immediate evacuation protocols, clear communication with the public, and collaboration with local emergency services are essential to limiting the impact on health and safety.

Here's a thirteen points comprehensive checklist to help you prepare a Crisis Management Plan for your organization:

1. Establish a Crisis Management Team (CMT):

• Identify team members from key departments (e.g., leadership, HR, IT, PR, legal, finance, medical, operations). If your company doesn’t have a medical department internal to your company, then create a collaboration with your nearest hospital and include their representative in your CMT, so that in case of an eventuality, everyone affected by the incident get best medical assistance at the soonest. 
• Also, include appropriate guidelines about how to save animals if any are present in/ around your premises and are likely to get affected by the crisis.
• Assign specific roles and responsibilities.
• Ensure team members are trained and informed about crisis procedures, applicable crisis management regulations in your country etc.

2. Identify Potential Crises:

• Conduct a risk assessment to identify potential crises (e.g., natural disasters, cyberattacks, operational failures, supply chain disruptions).
• Classify risks based on likelihood and impact.

3. Develop Response Strategies:

• Define action steps for each type of crisis. Make sure that your action plan totally complies with the law of your land.
• Outline a detailed containment and mitigation strategies, no shortcuts at all.
• Ensure strategies address both the internal and external communications.

4. Create a Crisis Communication Plan:

• Establish a communication chain of command.
• Identify spokesperson(s) for internal and external communications.
• Prepare message templates for media, employees, customers, community and stakeholders.
• Plan for regular updates during the crisis.

5. Outline Business Continuity Procedures:

• Prioritize critical functions that must continue during a crisis.
• Develop backup plans for operations, IT systems, and supply chains.
• Set up alternate work arrangements (remote work, backup locations).
• Ensure access to essential documents, resources, and contacts.
• You may want to watch my free videos about how to maintain business continuity in a crisis at my channel here.

6. Establish Emergency Protocols:

• Define evacuation, lockdown, and shelter-in-place procedures.
• Provide clear instructions for employee, customer and community safety.
• Ensure compliance with local safety regulations.

7. Develop a Post-Crisis Recovery Plan:

• Outline steps for recovery (e.g., financial recovery, restoring operations, community well-being).
• Plan for damage assessments and insurance claims.
• Establish timelines for a return to normal operations.

8. Create a Stakeholder Engagement Plan:

• Identify key stakeholders (e.g., employees, customers, partners, investors, vendors, regulators).
• Develop outreach and engagement strategies for each group.
• Maintain transparency and build trust during and after the crisis.

9. Test the Plan Regularly:

• Conduct regular crisis simulation exercises and drills. Keep a watch on global news citing safety breach incidents. Gather inputs on how they handled situations, what problems occurred, how were they sorted out etc. There’s a lot one can learn from such incidents and the learnings can be adopted into your company’s crisis plan.
• Review and revise the crisis plan based on feedback and lessons learned.
• Update contact lists and resource inventories regularly.

10. Document and Store the Plan:

• Ensure that the crisis management plan (physical and digital copies) is easily accessible.
• Distribute the plan to all relevant team members.
• Store important documents (e.g., contracts, insurance, vendor contacts) securely.

11. Assign Accountability for Plan Updates:

• Appoint a team or individual responsible for updating and maintaining the plan.
• Schedule periodic reviews of the plan to adapt to new risks, regulations, or business changes.

12. Compliance and Legal Considerations:

• Ensure the plan adheres to industry standards and legal requirements.
• Consult with legal experts to manage liability and compliance.

13. Integrate with Other Business Continuity Plans:

• Align the crisis management plan with overall business continuity, disaster recovery, and risk management strategies.
• Ensure coordination across all departments and functions.

This checklist provides a robust foundation for developing a customized comprehensive crisis management plan for your company, ensuring preparedness and minimizing impact of the crisis.

4. Community Engagement and Transparency
Operational excellence extends beyond the factory walls to the surrounding community. Building trust with local residents through regular communication, transparency about potential risks, and visible safety measures can reduce panic and improve public response in times of crisis. Offering community education on safety measures is another proactive step toward building operational excellence in your company.
​
To summarize, such companies must adopt a holistic approach to operational excellence that prioritizes safety, integrates advanced technology, prepares for crisis scenarios, and engages with the community. Proactively managing risks and being fully prepared for emergencies are key to minimizing the impact of any potential industrial incidents.

Keywords and Hashtags:
#GasLeak, #ChemicalSafety, #OperationalExcellence, #CrisisManagement, #IndustrialSafety, #RiskManagement, #EnvironmentalSafety, #EmergencyResponse, #CommunitySafety, #ProactiveSafety, #HealthAndSafety, #SafetyFirst, #ChemicalIndustry, #PublicSafety

​Categories:  Insights | Chemical Industry | Operational Excellence

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​This multi-part blogpost series presents practical answers to frequently asked questions on improving business entities. 

Its objective is to assist business leaders in these trying times, whether they are learning the basics of business process improvement, planning their first business improvement project, or evangelizing process-oriented thinking throughout their organization.
 
So, let’s get started … 
 
Cost of Quality refers to the entire sum that takes to produce a product or service while guaranteeing high standards of quality. This encompasses conformance as well as non-conformance costs, such as- costs allocated to repeat work, errors, and defects. For example, in the manufacturing industry, cost of quality can be increased by situations such as returned goods items.
 
There are a few different opinions that professional’s debate regarding Cost of Quality.
 
Few opine that, increased quality means increased cost. Enhancing features that relate to quality, such as performance and procedures, require more money for designing, sourcing materials, using labor and various other resources that add up significantly. Sometimes the added bonuses of quality improvement do not make up for the extra expenses.
 
Another opinion is that it costs less to improve quality of a product or service than it does to deal with the defects. Companies save more money since they do not have to spend it unnecessarily on costs that directly relate to defects. This concept is very popular among Japanese manufacturers.
 
Another popular opinion regarding Cost of Quality is that costs would be less if, a product or service were created in the optimal way right from start. This includes losses such as hidden expenses and missed opportunities.
 
Irrespective of the different Cost of Quality concepts, the criteria used to judge it remains the same, namely: production cost, internal and external failure cost, defect prevention cost, opportunity cost and inspection cost.
 
Internal failure cost refers to expenses incurred from defects found prior to reaching the customer and includes reviews, re-inspection, revision, and rework.
 
External failure cost refers to expenses involved with defects found once the product has reached hands of the customer and includes costs of product recalls, returns and warranty claims.
 
Prevention costs refer to the costs related to deterrence of quality that is lacking, such as training, reviewing and planning.
 
Inspection costs occur during the time that it takes to find out if a product or service fulfills the standard of quality that is required through testing and evaluation.
 
Therefore, lower the cost of quality, higher is the profit.
 
Hence, all technical and business processes undermining cost of quality must be regularly studied, improved or redesigned to make the business more efficient and profitable. This can be done by installing a culture of continuous improvement in your organization. 

​There are more than eighteen different business process improvement techniques. Check them out here.
 
I shall discuss more FAQs concerning effective & efficient business process improvement in upcoming parts of this blog post series...
 
By the way, if you run a company that is facing a challenge to thrive in these difficult times, I would suggest that you please revisit your business processes in order to accelerate growth and bring a quick turnaround.

Today USFDA announced addition of QR Code to certain export certificates for food products. This unique QR code will allow easier verification of the authenticity of the export certificates. ​

Beginning June 29, 2020, the "Certificate to a Foreign Government" and "Certificate of Exportability" for human food products will include a unique QR code to allow easier verification of the authenticity of these certificates.

This added security measure means that anyone who receives a certificate from a U.S. exporter can scan the QR code and see a copy of the certificate as issued by the FDA. The use of QR codes will expedite verification of FDA-issued export certificates compared to the current system.

You may view / download details of the QR code certificates here. 

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Keywords and Tags:
#ContinuousImprovement   #Innovation

To learn more about how Shruti can help your organization achieve new heights or to book a Workshop, Contact Dr. Shruti Bhat via Form or WhatsApp

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​Keywords and Tags:
#Kaizen  #KaizenTraining #KaizenLeaderMasterclass #ManufacturingExcellence #AgileKaizen #Lean #BPM #Manufacturing  #OrganizationalExcellence

About Shruti Bhat PhD, MBA, Certified Lean Six Sigma Black Belt
 
Dr. Shruti Bhat is an award-winning Business Excellence Leader, Global Continuous Improvement Mastermind, Best-selling Author and Speaker. She is Continuous Improvement Advisor to several start-ups, mid-size and growing firms in Canada, USA, India, Africa and Emerging markets. She has authored eight business books and is an invited speaker at several national and international conferences, symposia and workshops.


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Keywords and Tags:

​#Manufacturing #Lean #ContinuousImprovement #Kaizen  #QualityImprovement #Quality #FMEA #BPM    #BusinessProcessManagement  #ManufacturingManagement  #LeanManagement  #KaizenMasterclass  #LeanSixSigma  #Kanban  #RiskManagement  #Workshops

​A detailed root cause analysis shall of course open avenues of true ‘problem areas i.e. disjointed business processes’ which need correction, followed by a neat process improvement strategy and its flawless execution.​

​There are over eighteen different continuous improvement methodologies to choose from.

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Keywords and Tags:
​#OOS #OutOfSpecification #ProcessExcellence  #ContinuousImprovement #QualityImprovement  #ManufacturingManagement  #Pharmaceutical  #LifeSciences    #Drugs  #RiskManagement  #Lupin