A Strategy for the Control of Uncertainty and WIP: A Case Study Based on Lean Practices

Abstract

High works-in-process (WIP) levels usually involve significant losses for companies as they trigger dispatching delays, product shortages, increases in immobilized capital, and greater storage costs, among others. This study provides a strategy for gradually decreasing the WIP levels associated with the production line of a pharmaceutical company located in Latin America. The methodology used is based on Lean practices and, more specifically, organized into phases: the diagnosis of the current situation, information processing, mapping out the current situation through value stream mapping, analysis and determination of key factors for uncertainty control, and improvement proposals. The main tools used are value stream mapping, 5-whys, single-minute exchange of dies, and total productive manufacturing.