Lean Six Sigma untuk Mengurangi Waste Pada Produksi Tablet Coating A

PT. Medica Indonesia salah satu perusahaan farmasi etikal terbesar di Indonesia. Departement Pilot Plant berperan sebagai fasilitas peningkatan skala setelah skala lab untuk memastikan bahwa QTPP (Quality Target Product Profile) secara konsisten dicapai dalam skala pilot dan skala produksi. Masih tingginya angka reject sebesar 3,6 % dari target reject sebesar 0,5 % pada produk andalan tablet coating A merupakan suatu ancaman. Identifikasi penyebab pemborosan perlu dilakukan untuk peningkatan dan perbaikan pada lini produksi. Penelitian ini melakukan Integrasi Lean Six Sigma dengan menggunakan metode DMAIC, VSM dan VALSAT. Analisa menggunakan tools WRM dan WAQ. Berdasarkan Analisa VALSAT, ditemukan 3 pemborosan terbesar yaitu defect (38,47%), overproduction (16,32%) dan inventory (10,13%). Pemborosan diidentifikasi menggunakan diagram fishbone kemudian dari analisis FMEA menunjukan nilai RPN tertinggi yang dijadikan prioritas usulan perbaikan. Hasil menunjukan pengurangan defect ratio dari 10,35 % menjadi 1,65 % dan pengurangan waste inventory yang diakibatkan overproduction.

Lean Six sigma Integration to Reduce Waste in Tablet coating Production with DMAIC and VSM Approach in Production Lines of Manufacturing Companies

PT. Medica Indonesia was founded in 1969 and is one of the most significant ethical pharmaceutical companies in Indonesia. PT. Medica Indonesia, located in Cikarang, has a Pilot Plant Department that acts as a scale-up facility after lab scale to ensure that QTPP (Quality Target Product Profile) is consistently achieved on a pilot scale and a production scale. The high reject rate of 3.6% of the reject target of 0.5% for Tablet coating A products is a threat to the company because it can reduce productivity at PT. Medica Indonesia. Moreover, the Tablet coating A product is a mainstay product. In improving and improving the production line, it is necessary to identify the causes of waste. The integration of Lean Six Sigma using the DMAIC, VSM and VALSAT methods is an effective way to determine waste and the causes of waste. The analysis stage was carried out using the WRM and WAQ tools and determining recommendations for improvement using FMEA.

Validating a Numerical Simulation of the ConsiGma(R) Coater

Continuous manufacturing is increasingly used in the pharmaceutical industry, as it promises to deliver better product quality while simultaneously increasing production flexibility. GEA developed a semi-continuous tablet coater which can be integrated into a continuous tableting line, accelerating the switch from traditional batch production to the continuous mode of operation. The latter offers certain advantages over batch production, e.g., operational flexibility, increased process/product quality, and decreased cost. However, process understanding is the key element for process control. In this regard, computational tools can improve the fundamental understanding and process performance, especially those related to new processes, such as continuous tablet coating where process mechanics remain unclear. The discrete element method (DEM) and computational fluid dynamics (CFD) are two methods that allow transition from empirical process design to a mechanistic understanding of the individual process units. The developed coupling model allows to track the heat, mass, and momentum exchange between the tablet and fluid phase. The goal of this work was to develop and validate a high-fidelity CFD-DEM simulation model of the tablet coating process in the GEA ConsiGma® coater. After the model development, simulation results for the tablet movement, coating quality, and heat and mass transfer during the coating process were validated and compared to the experimental outcomes. The experimental and simulation results agreed well on all accounts measured, indicating that the model can be used in further studies to investigate the operating space of the continuous tablet coating process.