Discover your next big idea at PACK EXPO Las Vegas this September
Experience a breakthrough in packaging & processing and transform your business with solutions from 2,300 suppliers spanning all industries.
REGISTER NOW & SAVE

Small changes deliver big-time for Pharmacia & Upjohn

Pharmaceutical firm saves $650ꯠ/yr at its Kalamazoo, MI, packaging facility by implementing simple, yet cost-effective quick-changeover procedures on 30 packaging lines.

New computer hardware and software helps Pharmacia & Upjohn coordinate product changeovers. This screen illustrates some of the
New computer hardware and software helps Pharmacia & Upjohn coordinate product changeovers. This screen illustrates some of the

Last year, Bridgewater, NJ-based Pharmacia & Upjohn completed a three-year quick-changeover initiative (QCI) at its 33-acre manufacturing and packaging facility in Kalamazoo, MI, that saves the pharmaceutical firm more than $650ꯠ/yr.

QCI was one of several initiatives under an ambitious management strategy Pharmacia & Upjohn referred to as Global Supply Vision (see sidebar, p. 49). Two key quick-changeover concerns were identified:

* The exchange of parts on equipment to accommodate a different product, and

* The amount of time it takes to "ramp-up" the line to run at a steady, acceptable rate.

Confronting these concerns became the assignment for the QCI work team, headed by Wayne Johnson, packaging project manager; Steve Cornish, pharmaceutical operations specialist; and John Kroggel, a consultant from Prima Communications (Schoolcraft, MI), the company responsible for much of the technical documentation at the Kalamazoo facility.

Considering the size of the Kalamazoo plant, also called "Building 41," the QCI team had its work cut out for it. The complex houses 30 packaging lines that fill hundreds of items, including tablets, powders, ointments, blister-packed items, fluids and sterile products.

Targeting Line 24

"When we began the quick-changeover initiative three years ago, we were asked [by management] to target a line that had considerable changeovers," recalls Cornish.

"Line 24 [a tablet line] was changed over about 200 times last year," explains Johnson. Depending on which product is running, changeovers on that line can involve any or all of the line's nine major pieces of equipment, seven conveyor systems and five inspection systems. In sequence, the line includes a bottle unscrambler, desiccant feeder, tablet slat filler, cottoner, capper, induction sealer, labeler, cartoner or bundler.

Since most of the equipment on the line has been operational for years, this article will focus on changeovers rather than describe how each machine works.

Johnson says that initially the "quick-changeover team" planned to combine three lines (including Line 24) into two. "We went to management and said we could combine the lines and purchase new equipment that had quick-changeover capability built-in, at the cost of about $4 million. They came back and said let's look at the low-hanging fruit and do what we can without spending such a considerable sum."

"We pushed for repeatable changeovers so that when we went from product A to B, then back to A, the line could be set up quickly and easily," says Cornish. "But first we had to get a handle on the changeover process that was in place.

"We looked at the parts used to change a machine from one bottle size to another and made a list of those parts," he continues. "We developed a documented parts pick list [see Diagram A, p. 51] for each specific product with CCS [Corporate Coding System] numbers so that whoever was going to change the machinery on the line would know exactly what parts were needed for each piece of equipment. We also created a set-up checklist [Diagram B, p. 51] that would describe the steps that had to be taken and the proper settings each machine had to be set to in order to run a certain CCS number with the same repeatability. That information was entered into a database."

Phasing it in

Annual Outlook Report: Sustainability
The road ahead for CPGs in 2025 and beyond—<i>Packaging World</i> editors review key findings from a survey of 88 brand owners, CPG, and FMCG readers.
Download Now
Annual Outlook Report: Sustainability
List: Digitalization Companies From PACK EXPO
Looking for CPG-focused digital transformation solutions? Download our editor-curated list from PACK EXPO featuring top companies offering warehouse management, ERP, digital twin, and MES software with supply chain visibility and analytics capabilities—all tailored specifically for CPG operations.
Download Now
List: Digitalization Companies From PACK EXPO