Optimizing Material Flow by Applying Lean methodology

Abstract

This study examines how a stringent regulatory industry like the pharmaceutical industry could adopt modern operational practices like Industry 4.0 and Lean principles. This thesis presents a case study at AstraZeneca’s Material Management in Gothenburg, aiming to identify bottlenecks within lean principles and propose data driven improvements. Using methods like methodological triangulation by combining different methods such as Gemba walks, semi-structured interviews, and datasets. The research identifies multiple issues such as information flow as the primary bottleneck. Research hits communication issues between departments by providing incorrect documentation, creating waste, and defect wastes that cascade into secondary inefficiencies. The department also lacks Key Performance Indicators and cross-departmental transparency, resulting in a “black box effect”. The data also reveals a growing trend in reported issues year-over-year, suggesting that organizational growth introduces new operational challenge that current processes are not equipped to handle This study attempts to suggest possible solutions on KPI implementation, a visual process interface with checkpoints, standardized checklists, new communication channels, and an AI chatbot for inquiries attempting to replace static communication methods such as frequently asked questions