The Challenge: 398 Man-Hours per Batch
A pharmaceutical manufacturing operation was facing a high manual workload, with each batch requiring approximately 398 man-hours. Significant operator involvement was required across filling, inspection, material movement and documentation, resulting in high labour intensity, greater manual dependency and limited scalability. Skil Global assessed the end-to-end process to identify opportunities to improve workforce productivity while maintaining operational discipline.
What We Did: Following the Work, Minute by Minute
Skil Global conducted a time-motion study across unit operations, tracking operator activity minute by minute to understand where time and effort were being spent.
The study focused on filling and inspection, material movement, documentation and handling activities, separating essential work from repeated actions, unnecessary movement and fragmented workflows. This helped prioritise the highest-impact opportunities to improve workforce productivity.
The Transformation Roadmap: Simplify, Digitise and Automate
The roadmap followed a simplify-first approach, eliminating redundant activities and reducing unnecessary operator movement. Material handling and workflows were redesigned to minimise manual effort.
Automation opportunities were identified across visual inspection, packing and vial handling, supported by simplified equipment and one-touch operations.
Digitisation through electronic batch records and connected systems can further reduce transcription, streamline data capture and improve process visibility.
The Opportunity Identified: 398 to Approximately 162 Man-Hours
The assessment identified an opportunity to reduce man-hours per batch from 398 to approximately 162—a potential 59% reduction.
Monthly FTE requirements could fall from 15.3 to approximately 6.2, allowing workforce capacity to be redeployed to higher-value activities.
With less operator time tied up in manual work, the operation could potentially increase capacity from 7 to 9 batches per month, representing approximately 29% growth.
Why This Matters for Pharmaceutical Manufacturers
Reducing manual dependency is not simply about doing more with fewer people. It is about building a more scalable and productive operating model. By combining time-motion analysis, workflow simplification, automation and digital batch execution, manufacturers can reduce labour intensity, improve workforce productivity and create additional capacity without proportionally increasing headcount.
Can We Do This for You? Absolutely.
Your biggest productivity opportunity may already be hidden within your existing process.
Let’s connect for a 20-minute web meeting to explore a tailored roadmap for improving manpower productivity, reducing manual dependency and achieving breakthrough operational performance.
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If you’re facing similar challenges in your manufacturing process, write to us! Learn how you can achieve the same significant improvements in productivity and cost savings by implementing Lean Six Sigma tools.
