Shruti Bhat PhD, MBA, Lean Six Sigma Black Belt
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Kaizen Champion Certification Online Course

11/15/2018

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Glad to be invited as Course Director and Instructor for Kaizen Courses at Kaizen Leader Academy, Canada
Here are details of third course of the series...

Kaizen Champion Certification
kaizen champion certification online course, kaizen training

Kaizen Champion Certification Online Course is for Professionals at all levels of Management.

  • Learn how to select Kaizen projects, strategize, design and implement Kaizen continuous improvement campaigns.
  • Lean how to drive Kaizen projects successfully, create profits, reduce defects- overheads- errors, increase productivity- sales-market share- customer satisfaction. Take your company and career to the next level!
  • Learn in-depth about 9 types of Kaizen viz. Gemba Kaizen, Lean Kaizen, Modular Kaizen, Blitz Kaizen, Flow Kaizen, Process Kaizen, Personal Kaizen, Daily Kaizen, Agile Kaizen and how each Kaizen type can help you achieve success with your Kaizen initiatives.
  • The course has 6 Modules of self-paced study, training videos and instructor support, a Toolkit comprising 52 tools and 5 Case Studies that help you apply Kaizen to your organization.
  • The course includes videos showing real-time application of Kaizen in 5 reputed companies in US and Japan.

Participants must complete Tests and Assignments associated with each Module. All tests and assignments are open book exams. Kaizen Champion Certificate shall be sent to participants once they complete all tests and assignments successfully.

After successful completion of the course, participants gain the vision, knowledge and capacity to drive Kaizen implementation in their organization.

​#Kaizen #KaizenChampion #KaizenCertification 

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Kaizen Saved 30% Cost on Non-Automated Packing Lines and Logistics in a Food Factory; a Continuous Improvement Case Study

11/9/2018

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Learn how to use Kaizen to save 30% or more cost on non-automated packaging lines and logistics ...

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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#Manufacturing #Lean #ContinuousImprovement #Kaizen #QualityImprovement #FoodIndustry #ProcessExcellence #BusinessProcessManagement  #Beverage  #LeanManagement  #KaizenLeaderMasterclass  #Retail
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Workshops, Seminars & Online Course on Continuous Improvement by Dr. Shruti Bhat

11/6/2018

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​#ContinuousImprovement #Kaizen #Workshops  #ServiceIndustry  #ManufacturingManagement  #LeanInnovation  #Pharmaceutical  #LifeSciences  #Food  #Beverage  #Biotechnology  #Retail  #Cosmetics  #PersonalProducts  #Chemicals  #Drugs #Engineering #BPM  #LeanManagement  #KaizenLeaderMasterclass  #LeanSixSigma  
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Mistake-Proofing Pharmaceutical Product Development, Manufacturing and Logistics, Cost Savings via Poka Yoke

11/1/2018

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Do you have any of the following complaints:
  1. R&D is slow, doesn’t give out products on time?
  2. Too many backorders, products don’t leave factory on time?
  3. Too many failed batches in pilot plant during tech-transfer?
  4. Too many failed bio-studies?
  5. Accidents at workplaces?
  6. Cost of logistics is high; denting bottom-line?

If you have any of the above complaints (and more), then this post is for you. Do keep reading…
Mistake_proofing pharmaceutical product development manufacturing and logistics cost_savings via poka yoke
​Usually a defect is construed as a product defect. Pharmaceutical cGMP norms and other FDA regulations bring check to product defects from happening, as well as in most cases, check defective products reaching the patients.

A point to note is that, defects and rework happen in all areas of a pharmaceutical business, be it- R&D, Manufacturing, Logistics or Office work zones.  ​
In any business, including pharmaceuticals, defects and rework amount from 5% to as much as 30% of overhead expenses. Imagine what if your business could save all those dollars?
Implementing Poka Yoke allows you to 'Mistake-Proof' processes/ products, stop defects and rework. Poka Yoke is a Japanese term which means Mistake-proofing or Error-proofing inadvertent errors. Its purpose is to- eliminate product defects, stop re-work and save overall costs of operation or running the business.

Poka Yoke concept was first formalized and adopted in the auto industry to draw attention to human errors as they happen. It was originally described as Baka Yoke; ‘Baka’ in Japanese means an idiot or a fool. Baka Yoke meant idiot-proofing or fool-proofing. The name was later changed to a milder term- Poka Yoke; ‘Poka’ in Japanese means disengaged. Poka Yoke means mistake-proofing or error-proofing. Poka Yoke aims to prevent errors because of actively disengaged employees.

Poka Yoke is preventing errors caused by absent-mindedness. Baka Yoke is preventing errors when process standard is beyond human ability. Poka Yoke distinguishes between concept of inevitable errors (professing Murphy’s Law) and defects that happens because of lax processes and/or absent-mindedness of employees.

The consequence of defects in pharmaceuticals is grave when defective products reach the market- C&F agents, wholesalers, retailers, doctors, patients. Maximum damage is done when defective products are consumed by unsuspecting patients; while damage is minimal when defects are detected no sooner than they occur. 

The aim of Poka Yoke is to design the process (within a company) so that mistakes can be prevented or at least detected and corrected immediately so that it is eliminated at source. Poka Yoke can be implemented at any step of a R&D, manufacturing, logistics or office process, that is, all processes where something can go wrong or an error can happen.
​

How to do Error-Proofing?

Error-proofing in traditional pharma companies can be primarily done via three techniques, namely:
  1. Contact Method technique: contact method identifies defects by testing and inspection.
  2. Fixed-value or Constant number technique: This method alerts the employee if a certain number of movements are not made.
  3. Motion-step or Sequence technique:  This technique determines whether the prescribed steps of the process have been followed.

​In above instances, the employee is alerted when a mistake is about to be made (referred as warning Poka Yoke) or the Poka Yoke device actually prevents the mistake from being committed (referred as control Poka Yoke). By eliminating defects, the cost of mistakes within the company is reduced/ eliminated.

​Note that the error-proofing fronts increase if the organization is a smart factory, industry 4.0, operates as a multi-national or has many product mixes in its portfolio.

Poka Yoke is most effective when processes are accurately mapped. So, how to install Poka Yoke at your workplace?​

You may also like to read:

How to develop a culture of Continuous Improvement with your organization?
Decision making tool: Process Mapping
Continuous Improvement Case Study: Improved eyedrop dropper design and its process of making
How to install Poka Yoke in your organization?

A methodical approach to build up Poka Yoke countermeasures consist of three steps-
  1. Identify the need.
  2. Identify possible mistakes, mistake avenues
  3. Manage mistakes before satisfying the need.
 
​
Benefits of Poka Yoke implementation:

A foremost benefit of Poka Yoke solutions is that they don’t let an error happen in a process. Other benefits include:
  1. Eliminates rework.
  2. Reduces cost on employee training.
  3. Reduces product analysis cost.
  4. Reduces QA/ QC workload.
  5. Improved productivity from R&D, manufacturing and other divisions of the organization.
  6. Improved safety at workplace- no personal injury, prevents machine/ facility damage.
  7. Motivated employees.
  8. Promotes product innovations and defensive designs: Defensive design is building contingencies in the design to anticipate all potential ways an end-user could misuse or make a mistake. For example, power sockets are often keyed in such a manner to prevent the transposition of live and neutral. The plug is inserted into the socket in a specific orientation; hence the plug is designed so that it is physically impossible to insert the plug incorrectly.
  9. Immediate action when a problem occurs.
  10. Unburdens employees from repetitive operations, makes processes ‘Lean’ and efficient- Saves Cost

​
​Learn more about ‘How to mistake-proof your R&D, Manufacturing, Logistics and Office processes and gain quick cost-savings’. Contact Us

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#Manufacturing #ContinuousImprovement  #QualityImprovement #Quality  #Impurities   #ManufacturingManagement   #Pharmaceutical  #LifeSciences  #RiskManagement​  #Valsartan #Losartan #Irbesartan   #MistakeProofing
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Transforming businesses from good to great ! Dr. Shruti Bhat's Article Published in Express Pharma

5/15/2016

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Dr. Shruti Bhat's article on page 37, published in GMP and Quality, special issue of Express Pharma, SE Asia's #1 Trade magazine.
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#ContinuousImprovement #BusinessProcessManagement  #BPM  #LeanManagement  #Kaizen #LeanSixSigma  
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Innovation bytes: 3D Printed drones for distribution- supply chain logistics process improvement.

2/2/2016

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3D Printing is revolutionizing distribution and supply chain logistics processes. Besides saving zillions of dollars, it's environment friendly too.
3D printed drones for distribution supply chain logistics process improvement
An example: Airbus isn't content with 3D printing motorcycles -- it's crafting aircraft, too. The aviation giant used the recent Berlin Air Show to introduce 'Thor', a drone built almost exclusively from 3D-printed parts.

Detailed report click >>>

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Streamlined Process Improvement - A shortcut technique for improving business efficiency and profit.

9/25/2015

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It is normal for organizations to find themselves in a rut since many processes become ingrained due to repetition. An easy solution is Streamlined process improvement.
streamlined process improvement_ A shortcut technique to improve business efficiency and profit
Streamlined process improvement refers to the improvement of a process by reducing and shortening the amount of steps in a process in order to lower its intricacy. It is beneficial since it helps cut back on costs, uses time more effectively and efficiently and increase supervisory observance. Streamlined process improvement is a part of lean six sigma methodology. Organizations can benefit from using streamlined process improvement in order to gain a competitive advantage.

This type of process of improvement not only increases value for customers but also reduces waste.

It aims to boost customer value by using fewer means while improving the satisfaction of customers. It is a methodical method to gaining further insight into the processes of business as well as better handling of the various processes. Streamlined process improvement lowers costs, provides higher quality products (or services) and increases distribution efficiency leading to improved sales. 

A proven DIY (Do -it- yourself) technique to starting streamlined process improvement within your organization is to gain insight from members of the organization by finding out their ideas on ways in which workflow can be improved. The best way to develop a well-rounded opinion is to find out as much information as possible from a variety of staff including managers and employees.  

Second step in streamlined process improvement- the organization needs to focus on one particular work process. The work process is defined as a fixed, recurring method that has clear stages from the beginning to the end. An example of a work process to focus on is delivering payroll. The work process must then be broken down into as many distinct stages as possible. It is beneficial to have refined stages. Employees can provide valuable insight into various stages that managers may not be aware of.  

It is vital to gather information from those involved in the workflow process by asking for their thoughts regarding productivity improvement. The aim of this is to find out ways to improve the efficiency of entire workflow and not simply the efficiency of the staff. 
Workflow enhancements can then be implemented by beginning with the most obvious part of a repetitive and redundant workflow procedure. Sometimes the solution is as simple as removing a single stage of a process that was once applicable but no longer serves the process as a whole. The stages are then repeated with focus on each workflow problem in order to improve the entire process in increments.



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#Manufacturing #ContinuousImprovement #SixSigma  #QualityImprovement  #BusinessProcessManagement  #ServiceIndustry  #ManufacturingManagement  #LeanInnovation  #BPM  #LeanManagement  #KaizenLeaderMasterclass  #LeanSixSigma  #StreamlinedProcessImprovement #BusinessEfficiency
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    New Book Released!

    kaizen for pharmaceutcials, medical devices and biotech industry book by Dr Shruti Bhat
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    Shruti Bhat
    PhD, MBA
    Certified Lean Six Sigma Black Belt

    ​Shruti is a ​Global Leader in Lean Innovation, Lean Manufacturing, Business Transformation and Continuous Improvement; Best-Selling Author and Speaker.

    Shruti is a Go-To Scientific Expert and Management Leader within Pharmaceutical, Health Care, Device Technology, Bio- Technology, Life Sciences, Retail industry  and affiliated verticals.

    Shruti is a true 
    Thought Leader, who has ​accomplishments, awards, books, patents and several publications in peer reviewed journals. ​
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