OPERATIONS MANAGEMENT PROJECT

INTRODUCTION

Leading Pharmaceutical company of India. Ranks 58th out of 22000 operating pharmaceutical companies in India. Annual sales turnover Rs. 87 crores. Production units - Ghaziabad, Bangalore, Bhopal and Kolkata

Core competency Manufacturing Pharma formulations , infusion solutions, herbal products, bulk drugs and disposable syringes and needles
Ghaziabad unit was established in 1981 Its employee strength is 467 Ghaziabad unit covers 27000 retail outlets. Main products - Infusion solutions and oral solids

OBJECTIVES
To learn about the processes involved in the production of antibiotics. To learn about the processes involved in the production of glucose and saline solution. To study the contribution made by their information system towards the operational efficiencies. To learn about the functioning of various machines and their integration with the help of PLC methodology Suggest recommendations, if any, to improve the efficiency and quality control measures of the unit.

THE EXISTING SYSTEM

GENERAL MANAGER

FINANCE MANAGER

PRODUCTION MANAGER

INSPECTION MANAGER

MARKETING MANAGER

R & D is conducted at Calcutta unit Set of administrative and support staff 2 occupational groups of plant workers One for maintaining equipment and inspection Others specialize in one part of production process A set of support workers drive industrial trucks or move material within the unit

INSPECTION

Inspection involved at every step Examination of

Materials received from suppliers Components and assemblies Final check on Finished Products

Sometimes entire lot is rejected outright Extensive statistical measures used Very narrow level of errors accepted

ROLE OF IT
Computers- integral part of industrial

production
Computers are networked Plays a vital role in transforming manual process

to semi-automated machines and semi-automated machines to fully automated ones

PLC METHODOLOGY
Introduced in April, 2006. Breaks down each manufacturing module into a

pyramid of smaller and smaller process steps High growth rate of industry necessitates expansion every 30 months PLC helps to automate the whole process there by increasing efficiency

THE PRODUCTION PROCESS(1/3)

Competitive Priorities are Timely Delivery and Stringent Quality Measures Capacity of IV solutions are measured in terms of Bottles per day Present production is around 80,000 bottles per day, which is about 85% of actual capacity Raw Material Storage Period: 30 days in case of indigenous medicines, 2 months in case of imports

THE PRODUCTION PROCESS(2/3)

TABLET MANUFACTURING PROCESS:

THE PRODUCTION PROCESS(3/3)

INTRA-VENOUS SOLUTION MAKING PROCESS:
Raw Feed Water Desired Constituents

Deionization Chamber

Mixing Chamber Distillation Chamber

Final Solution Blow Fill Seal Machine Programmable Logic Controller PID Tuning Blow Fill Seal Subsystem Plastic Temperature Control Highly Purified Water

IV Fluid Package

Packaging Equipment

PLANT LAYOUT

QUALITY MANAGEMENT
Quality of final product is one of the competitive priority of Albert David. Measures for quality control : Quality Control department. Quality Assurance department.

Certification in Quality Standards: Certificate of Good Manufacturing Practices as per WHO. ISO 9002 certification from SGS Yarsley U.K.

RECOMMENDATIONS

Adjustment in layout is required. Automated dispensers should be used in place of manual Dispensers. Use Quality-by-Design instead of quality-by-testing. JIT should be implemented. Implement Process Analytical Technology (PAT).

THANK YOU