Value Stream Mapping and Simulation Techniques for Considering Bottleneck Reduction Alternatives: A Case Study in A Sterile Pharmaceutical Factory
Article Sidebar
Main Article Content
Abstract
In today’s competitive market, pharmaceutical companies strive to meet international standards for their production methods while keeping an eye on production costs. Therefore, it is important to eliminate non–value–added activities. This research proposes a method to improve the process of sterile pharmaceutical factory of generic drugs through simulation techniques. Data needs to be collected on production volume, production cost, and cost of defect. In this study, a Pareto chart was used to identify a high–priority product that needed to be improved. A value stream map of the current process was created, providing a comprehensive overview, including bottlenecks. Plant simulation software (Tecnomatix®) was used to test by developing three different scenarios. The efficiency of production line balancing was increased by reducing the bottleneck in the filling process. The study analyzed the current process, which takes 2 days 5 hours 47 minutes 57 seconds. Three scenarios were then tested using plant simulation software. Scenario 1 involved adding additional labor, reducing the processing time to 2 days 1 hour 48 minutes 27 seconds (a decrease of 7.42%). Scenario 2 focused on labor rotation, achieving a time reduction to 2 days 4 hours 7 minutes 16 seconds (a decrease of 3.12%). Finally, scenario 3 explored changing machinery, resulting in the most significant improvement, with a processing time of 1 day 20 hours 27 minutes 12 seconds (a decrease of 17.37%). In scenario 3 reducing employee expenses by 6.00%, there is a cost for new machinery with a long–term return on investment, which is beneficial in cases where future production demand increases. Because the machinery can sufficiently contribute to enhancing efficiency in both quantity and quality aspects.
Article Details
This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
Article Accepting Policy
The editorial board of Thai-Nichi Institute of Technology is pleased to receive articles from lecturers and experts in the fields of engineering and technology written in Thai or English. The academic work submitted for publication must not be published in any other publication before and must not be under consideration of other journal submissions. Therefore, those interested in participating in the dissemination of work and knowledge can submit their article to the editorial board for further submission to the screening committee to consider publishing in the journal. The articles that can be published include solely research articles. Interested persons can prepare their articles by reviewing recommendations for article authors.
Copyright infringement is solely the responsibility of the author(s) of the article. Articles that have been published must be screened and reviewed for quality from qualified experts approved by the editorial board.
The text that appears within each article published in this research journal is a personal opinion of each author, nothing related to Thai-Nichi Institute of Technology, and other faculty members in the institution in any way. Responsibilities and accuracy for the content of each article are owned by each author. If there is any mistake, each author will be responsible for his/her own article(s).
The editorial board reserves the right not to bring any content, views or comments of articles in the Journal of Thai-Nichi Institute of Technology to publish before receiving permission from the authorized author(s) in writing. The published work is the copyright of the Journal of Thai-Nichi Institute of Technology.
References
N. Tunpaiboon. “Industry Outlook 2023-2025 : Pharmaceuticals.” KRUNGSRI.com. https://www.krungsri.com/en/research/industry/industry-outlook/chemicals/phamaceuticals/io/io-pharmaceuticals-2023-2025 (accessed Feb. 1, 2023).
Department of Older Persons, “Elderly People Statistics,” 2023. [Online]. Available: https://www.dop.go.th/th/statistics_page?cat=1&id=2
W. Atthirawong, N. Prakotwong, C. Wongsiachua, P. Inchan, and R. Singseang, “Improvement of production line of frame sub–assembly seat support: A case study of Thai Summit Gold Press Co., Ltd.,” (in Thai), Thai J. Oper. Res., vol. 4, no. 2, pp. 1–9, 2016.
M. Kikolski, “Study of production scenarios with the use of simulation models,” Procedia Eng., vol. 182, pp. 321–328, 2017.
J. Siderska, “Application of Tecnomatix plant simulation for modeling production and logistics processes,” Bus. Manag. Educ., vol. 14, no. 1, pp. 64–73, 2016.
P. A. Russkikh and D. V. Kapulin, “Simulation modeling for optimal production planning using Tecnomatix software,” J. Phys.: Conf. Ser., vol. 1661, 2020, Art. no. 012188.
R. Chiangthong, T. Tresirichod, and K. Chienwattanasook, “Application of tecnomatix plant simulation to improve the quality inspection process,” J. Liberal Arts Service Ind., vol. 5, no. 1, pp. 383–395, Feb. 2022.
Y. Feng and G. Gao, “Design and simulation study on logistics planning in automatic plant factory based on Tecnomatix plant simulation,” in Proc. 2nd World Conf. Mech. Eng. and Intell. Manuf. (WCMEIM), Shanghai, China, Nov. 2019, pp. 667–671.
P. Trebuna, M. Pekarcikova, and M. Petrik, “Application of Tecnomatix process simulate for optimisation of logistics flows,” Acta Montanistica Slovaca, vol. 23, no. 4, pp. 378–389, 2018.
P. Trebuna, M. Pekarcikova, and M. Edl, “Digital value stream mapping using the Tecnomatix plant simulation software,” Int. J. Simul. Modelling, vol. 18, no. 1, pp. 19–32, 2019.
M. Kikolski, “Identification of production bottlenecks with the use of plant simulation software,” Eng. Manag. Prod. Services., vol. 8, no. 4, pp. 103–112, 2016.
S. Islam, S. Sarker, and M. Parvez, “Production efficiency improvement by using Tecnomatix simulation software and RPWM line balancing technique: A case study,” Amer. J. Indus. Bus. Manag., vol. 9, no. 8, pp. 809–820, Apr. 2019.
A. Kengpol and K. Elfvengren, “Avoiding Covid-19 using a 3d digital mock up and augmented reality with Cobot in digital factory,” Appl. Sci. Eng. Prog., vol. 15, no. 3, Art. no. 5624, 2022.
S. Bangsow, Tecnomatix Plant Simulation: Modeling and Programming by Means of Examples, 2nd ed. Cham, Switzerland: Springer Nature, 2020
O. Qassim, J. A. Garza-Reyes, M. K. Lim, and V. Kumar, “Integrating value stream mapping and PDCA to improve the operations of a pharmaceutical organisation in Pakistan,” in Proc. 23rd Int. Conf. Prod. Res., Manila, Philippines, Aug. 2015.
M. E. Nenni, L. Giustiniano, and L. Pirolo, “Improvement of manufacturing operations through a lean management approach: A case study in the pharmaceutical industry,” Int. J. Eng. Bus. Manag., vol. 6, no. 24, 2014, doi: 10.5772/59027.
Pramadona and A. Adhiumata, “The application of lean manufacturing for operation improvement: A case study of black cough medicine production in Indonesia,” Asian J. Technol. Manag., vol. 6, no. 1, pp. 56–64, 2013.
K. Kovbasiuk, K. Zidek, M. Balog, and L. Dobrovolska, “Analysis of the selected simulation software packages: A study,” Acta Technologia, vol. 7, no. 4, pp. 111–120, 2021.
M. Rostkowska, “Simulation of production lines in the education of engineers: How to choose the right software?,” Manag. Prod. Eng. Rev., vol. 5, no. 4, pp. 53–65, 2014.
A. M. Law, Simulation Modeling and Analysis, 5th ed. Boston, MA, USA: McGraw-Hill, 2014.
W. J. Stevenson, Operations Management, 13th ed. New York, NY, USA: McGraw-Hill Education, 2018.
J. Heizer and B. Render, Operations Management, 10th ed. Boston, MA, USA: Pearson, 2011.
F. W. Taylor, The Principles of Scientific Management. New York, NY, USA: Harper & Brothers, 1911.
