HFL Consulting

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The Challenge

Piramal is a world-leading custom manufacturing organisation.

The site is an integrated API & Formulations site with scale-up and commercial manufacturing capabilities. It routinely supplies over 300 finished dosage forms and SKUs (stock keeping units) to more than 100 markets worldwide.

The company initially approached us with a primary aim of bringing about efficiency gains.

The Solution

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Workflow Analysis

Our consultants initially focused on workflow analysis, looking at how tasks were handled on a day to day basis and ways in which inefficiencies and wastage could be eradicated.

Root Cause Analysis

Engineers and technicians undertook our training courses in 1st and 2nd level analysis which has now been embedded into the day to day activities at the plant, with the most significant breakdown of any working week now regularly examined in depth using scientific techniques.

FMEA

We worked with the team on Failure Mode and Effects Analysis (FMEA) which offers a structured approach to the prediction of potential failures. Solutions to the potential failures are then prioritised so that the most significant ones are dealt with first.

Key Services

Business Diagnostics

Value Stream Mapping

Diagnostics - Workflow and Data Analysis.

Reliability

Root Cause Analysis

Training – Equipping engineers and technicians with the tools and techniques to investigate day-to-day problems

Risk Assessments

FMEA

Facilitated assessments to identify potential failures and put measures in place to reduce the likelihood of occurrence.

The Results

The Results

With our help and guidance, the Piramal team have gained new skills and insight, and have been able to implement a structured programme that has substantially improved plant reliability. This has resulted in cost savings of around £100,000 per year.

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    Hundreds of maintenance man hours eliminated
  2. 02
    General feel-good factor that comes with the successful application of any change-programme

The work we did here was about value stream mapping certain tasks and identifying waste. Engineers, operators and maintenance technicians worked with the team to analyse tasks and look at ways we could take a more structured, scientific approach to bring about efficiency gains

Michael Devenport, Engineering Manager - Piramal

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