Process workflow optimization and redesign for packaging line at a medical device company

Abstract

This document describes the process of workflow optimization and redesign using Lean Six Sigma tools to better understand the Ivers Lee packaging lines (IL#1 and IL#2) issues and create alternatives to improve them. This is the case of two (2) packaging machines that were built in the 1960’s and are currently packaging approximately seventythree (73) million surgical blades per year. This is a manual filling, packaging and labeling process that implicates significant intensive labor tasks. This area currently faces several challenges. The main challenge is to increase the labor usage while balancing operator tasks. As project goals, these include increasing process consistency, improving capacity and utilization of resources to optimize production and maximize efficiency. Key Terms  Lean Six Sigma, Line Balancing, Time Studies, Work Improvement.