SOP Guide for Pharma

Tablets: SOP for Implementation of Lean Manufacturing in Tablet Production – V 2.0

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Tablets: SOP for Implementation of Lean Manufacturing in Tablet Production – V 2.0

Standard Operating Procedure for Implementation of Lean Manufacturing in Tablet Production

Department Tablet
SOP No. SOP/TAB/059/2025
Supersedes SOP/TAB/059/2022
Page No. Page 1 of 8
Issue Date 05/12/2025
Effective Date 10/12/2025
Review Date 05/12/2026

1. Purpose

The purpose of this Standard Operating Procedure (SOP) is to outline the process for implementing lean manufacturing principles in tablet production. The goal is to optimize efficiency, reduce waste, and improve overall product quality by adopting lean techniques across the manufacturing process.

2. Scope

This SOP applies to the entire tablet production process, including raw material handling, granulation, compression, coating, and packaging. It covers the application of lean tools and techniques to eliminate waste, improve workflow, and enhance productivity in tablet manufacturing.

3. Responsibilities

4. Accountability

The Production Manager is accountable for overseeing the implementation of lean manufacturing in tablet production and ensuring that processes are optimized for efficiency and quality. The Lean Manufacturing Team is responsible for leading continuous improvement initiatives, while the QA Manager ensures that all changes are in compliance with GMP standards.

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5. Procedure

5.1 Identifying Areas for Improvement

  1. Conduct a thorough review of the entire tablet production process to identify areas of waste, inefficiency, or potential improvement. Key areas to focus on include:
    • Material handling and inventory management
    • Machine setup and downtime
    • Batch changeover times
    • Packaging and labeling processes
  2. Use lean tools such as value stream mapping (VSM) to visually identify waste in the production flow and bottlenecks in the process.
  3. Engage the production staff in brainstorming sessions to gather insights on inefficiencies and potential solutions.
  4. Prioritize areas for improvement based on their impact on productivity, quality, and cost reduction.

5.2 Implementing 5S for Workplace Organization

  1. Implement the 5S methodology (Sort, Set in order, Shine, Standardize, Sustain) to organize the tablet manufacturing area for improved efficiency and safety.
  2. Sort: Remove unnecessary tools, materials, and equipment from the production floor to eliminate clutter.
  3. Set in order: Organize tools and materials in a logical order to minimize searching and handling time.
  4. Shine: Clean the workspace and equipment to maintain a safe and efficient production environment.
  5. Standardize: Create standardized procedures for cleaning, organizing, and maintaining equipment and materials.
  6. Sustain: Establish a system for monitoring and maintaining the improvements made through the 5S process to ensure continued compliance.
  7. Ensure all personnel are trained on the 5S principles and their role in maintaining an organized and efficient work environment.

5.3 Implementing Just-in-Time (JIT) Inventory Management

  1. Adopt Just-in-Time (JIT) inventory management to reduce inventory levels, minimize waste, and ensure that materials are available only when needed in the production process.
  2. Work closely with suppliers to align delivery schedules with production needs, reducing the need for large inventories and minimizing stockouts or overstocking.
  3. Implement Kanban systems to trigger material replenishment based on actual production needs, ensuring efficient material flow and reducing excess inventory.
  4. Monitor the effectiveness of JIT and make adjustments as necessary to align with production demands and lead times.
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5.4 Reducing Setup and Changeover Times

  1. Analyze current setup and changeover times for tablet manufacturing equipment and identify opportunities for improvement.
  2. Implement Single-Minute Exchange of Die (SMED) techniques to reduce setup time and improve equipment utilization.
  3. Standardize changeover procedures to minimize downtime and streamline the process. Ensure that all tools and materials needed for setup are readily available and properly organized.
  4. Train personnel to perform quick and efficient changeovers to reduce production delays between batches.
  5. Monitor the effectiveness of setup reduction initiatives and adjust processes as necessary to further minimize downtime.

5.5 Standardizing Work Processes

  1. Develop and implement standardized work procedures for all tablet manufacturing processes, ensuring consistency and reducing variations in product quality.
  2. Utilize lean tools such as standard operating procedures (SOPs), checklists, and visual aids to provide clear instructions for operators and reduce errors.
  3. Regularly review and update work standards to reflect process improvements, equipment changes, and new regulatory requirements.
  4. Involve operators in the development of standard work procedures to ensure they are practical and effective.

5.6 Continuous Improvement and Kaizen

  1. Establish a continuous improvement culture by encouraging operators to regularly suggest improvements to the manufacturing process (Kaizen).
  2. Set up regular Kaizen events where cross-functional teams can work together to identify issues, implement improvements, and track results.
  3. Ensure that all improvements are documented and that lessons learned are shared across the production team.
  4. Recognize and reward team members for contributing to continuous improvement efforts, fostering a culture of innovation and efficiency.

5.7 Monitoring and Measuring Lean Manufacturing Performance

  1. Establish key performance indicators (KPIs) to measure the success of lean initiatives, such as:
    • Cycle time
    • Overall Equipment Efficiency (OEE)
    • Inventory turnover
    • First-pass yield
  2. Regularly review these KPIs to assess the impact of lean initiatives on productivity, quality, and cost reduction.
  3. Make adjustments as necessary to further optimize the process and ensure that lean principles are being effectively applied.
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5.8 Documentation and Record-Keeping

  1. Document all lean manufacturing initiatives, including process improvements, changeover reductions, and inventory management adjustments, in the batch record (Annexure-1).
  2. Maintain records of all training activities related to lean manufacturing and 5S implementation (Annexure-2), and ensure that these records are available for future audits or inspections.
  3. Ensure that all changes to work processes, equipment, or SOPs are documented and signed off by the appropriate personnel.

6. Abbreviations

7. Documents

  1. Batch Record (Annexure-1)
  2. Lean Manufacturing Training Records (Annexure-2)

8. References

9. SOP Version

Version: 2.0

10. Approval Section

Prepared By Checked By Approved By
Signature
Date
Name
Designation
Department

11. Annexures

Annexure-1: Batch Record

Batch Number Lean Process Parameters Efficiency Improvement Comments
Batch 001 Reduced setup time by 10 minutes Improved production rate by 15% No deviations

Annexure-2: Lean Manufacturing Training Records

Employee Name Training Date Training Topics Instructor
John Doe 01/11/2025 5S, JIT, Lean Tools Jane Smith

Revision History:

Revision Date Revision No. Revision Details Reason for Revision Approved By
01/01/2024 1.0 Initial Version New SOP Creation QA Head
01/02/2025 2.0 Updated Lean Implementation Techniques Improved Process Efficiency QA Head
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