Process Optimization in Packaging Lines

Abstract

Viatris, a global pharmaceutical leader, undertook a transformative operational optimization project focused on Packaging Line 6, a critical component of its supply chain. This initiative was launched to address significant inefficiencies, including 39% idle time, excessive operator movement, and manual processes that inflated labor costs and reduced productivity. With four operators per line and over 300 feet of in-process travel per batch, the system was strained by waste, poor layout design, and underutilized talent. The project aimed to modernize workflows, reallocate 25% of the workforce without sacrificing output, and align operations with Viatris Hungary’s more efficient three-operator model. The strategy combines digitalization, automation, ergonomic improvements, and workforce optimization. Key achievements include a 76% reduction in travel distance between inspection stations (from 609 to 144 feet), a 31% decrease in standard travel time, and a 22.5% overall reduction in operator movement. These physical improvements were supported by cross-training operators, introducing automated palletizing (which cut palletizing time by 80%), repositioning Kronos terminals to save 91 feet of travel per cycle, and implementing a control system with a KPI dashboard for sustained compliance. Financially, the project demonstrates a compelling return on investment, with implementation costs of $128,950 and projected annual savings exceeding $315,000 yielding a payback period of just 17 months. These results validate not only the operational but also the economic viability of the initiative. Beyond cost savings, the redesign enhances regulatory compliance, improves employee well-being, and supports long-term sustainability goals.