Although India is the largest provider of generic drugs globally and the second-largest contributor to the global pharmaceutical workforce, an increase in operational costs, human errors, reserved inventory, lack of proper maintenance, and safety culture have become a major challenge.

Problem Identification

The bottleneck for this pharmaceutical company was reduced production volume caused by:

(a) Inability to repair the vacuum pumps within the speculated time,
(b) Premature break-down of the machines due to poor maintenance.

Due to the complexity of equipment and the continuous changes that occur due to high attrition rates, the service technicians were unable to meet the required skill level to keep the plant running efficiently, resulting in increased running costs and a decrease in the quality and quantity of service.

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