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Intermediate Yield Improvement
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(May 25, 2020)
     

Intermediate yield improvement project. We are manufacturing this Intermediate product at Lupin Ankleshwar since last 20 years and a lot of development work has been done in the last decade to get molar yield of each stage above 70%.The yield since the last 4 years is almost stable in this product.

Looking at the complexity of the product, initially it seemed very difficult to improve it further and then, we adopted the Lean Six Sigma methodology for this project. Voice of Internal & external customers was identified and the goal was decided with baseline value of last one year. The potential saving of Rs 9 Cr is validated by our Finance team (Money Belt). Black Belt (Project Leader) & Sponsor were selected on the basis of performance rating of the last 3 years. Cross functional team (Yellow belts) was also identified from Production, Process Engg, Process development, QC & Engineering departments. Black belt underwent three weeks of DMAIC training while yellow belts were underwent 2 days of introductory training. Rigorous Toll gate review was done to ensure the project deliverance at each phase of DMAIC cycle. Cross functional teams were regularly involved in the Project to identify all possible potential causes at each step. As per pre-defined communication schedule, weekly two meetings with team & weekly one meeting with sponsor is followed. Various Non-data techniques (VSM, CE matrix, FMEA etc.) as well as data techniques (2 Sample T test, ANNOVA, Regression, DOE etc.) were used to drill down 100 of Xs to few critical parameters in each step. On successful completion of this Project, we achieved operational Metrics 0.264 yield against 0.247 with Rs 9 Cr annual saving.

Apart from the tangible benefits, we achieved many other benefits like Second Line leadership development, utility reduction, Effluent reduction, team involvement, systematic problem solving approach in all the individuals with the help of statistical tools etc.

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