After implementing the Telstar Operating System (TOS), an own management system of lean manufacturing process based on Kaizen methodology, the company has significantly increased its efficiency by 12% throughout 2015. Fully operational since October 2014, the initiative has had a particular impact on quality work processes and facilitates the comprehensive management under a lean manufacturing concept. Telstar has foreseen improving efficiency by at least an additional 10% in 2016.

The management system provides comprehensive tools in order to reduce internal MUDA and optimize internal processes, focusing on increasing quality, cost and cycle time optimization and reducing delivery times. The implementation of the high-standard quality management system leads Telstar’s brand to be aligned with the practice of most competitive pharmaceutical and biotechnology companies, which have adopted similar quality management systems.

Quality Gates

The Quality Gates, which is part of the Telstar Operating System, is one of the first innovative tools implemented in the organization together with the project risk management. With the aim of increasing accuracy, reducing risk, reducing non-quality cost and increasing client satisfaction, The Quality Gates is a tool to ensure the fulfillment of quality requirements at each project stage through prevention, detection, and containment of abnormalities. It is a project management tool which standardizes the way of managing the projects and minimizes project variation. An internal customer is defined by the company for each stage of the project whose requirements needs to be completely satisfied before continuing and reaching the next project stage. The connections / outputs expected on each project stage need to be compliant and are clearly defined in a checklist.This internal management tool enables Telstar to visualize and manage the problems when they appear applying stop/fix methodologies if necessary thus ensuring total process efficiency.

First results

The implementation of the innovative Telstar Operating System has also had immediate effect for some standardized equipment such as freeze-dryers for laboratory applications for small assembly cells. Throughout 2015, the manufacturing process of this kind of equipment has undergone a standard time reduction of 20%, as well as a reduction of the non-quality costs, an improvement of the delivery lead time to the customers and a reduction of the number of customer incidences.

The pilot phase of the different tools included in the Telstar Operating System is being implemented at the facility in Terrassa (Barcelona), the company’s largest manufacturing plant. Telstar, part of the azbil Group, will progressively apply the new operational management system to all its technologies, projects, business units and, finally, all its centers and subsidiaries.

Efficient tools

Tools like 5S, Quality Gates, Project Teams, Value Stream Mapping, 8Dreports,Visual Dashboards, 5W’s and fishbone root cause analysis, project risk analysis, Design Processes standardization, among others, are part of the new management system TOSand are widely used in the organization providing important internal MUDA reductions.

However, it is not the first time that the company has used a new technological process focused on control projects in earlier stages of execution to ensure the process quality and efficiency. The advanced simulation technology REVIT, part of the Building Information Model within Telstar’s engineering services, has also being used since 2013 for all construction projects managed by the company in the engineering phase of projects of construction of pharmaceutical plants. It provides control over the entire life cycle of the building and its installations and its implementation results an average saving of 20% in time and costs.

For the company, the new approach of standardizing the management of the different projects and activities within the organization reinforces the competitive advantages of the company, the product diversity and its flexibility to adapt to customer demands, which are essential for the Telstar business in the future. This standardization settles the basis for the continuous improvement which the organization is aiming.

Fuente: Telstar

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