Cycle Time Reduction of a Crystallization Process in a Chemical Plant

Abstract

Estimates indicate that Diabetes will increase affecting the population worldwide in the future. To mitigate current and future demand, Barceloneta’s Factory 2 needs to improve the active pharmaceutical ingredient (API) for Diabetes Type II manufacturing process. Several stages in the manufacturing process have been identified for improvement. This project focuses in the Cycle Time Reduction of a Crystallization Process. Six Sigma tools and methodologies (Define, Measure, Analyze, Improve and Control) were utilized to identify the problem and improve the process. As a result we were able to optimize the crystallization process, reducing the cycle time to ≤ 20 hrs of the vessel and helping the train ability to increase its manufacturing capacity with an output 6.0 lots per week in 5 days / 3 shift. Key Terms - Cycle Time, DMAIC, Prioritization Matrix, Process Baseline.