Case No 2

Optimising Production Processes

Initial Situation
Shortening Process Lead Time (PLT) in Pharmaceutical Companies


  • GMP Compliance 100% 100%
  • Reduction in cycle time 30% 30%
  • Reduction in material movements 50% 50%


  • Analysis of the process steps by GEMBA Walk
  • Identification of the weak points or wastes
  • Visualisation of human and material movements using a spaghetti diagram over a defined period of time
  • New process layout with reduced or shorter transport routes
  • Improving the use of space by changing the laboratory equipment
  • Summary of activities