Proc.

of the 1st International Conference on Modern Trends in Industrial Engineering, November 17-19, 2011

S.V. National Institute of Technology, Surat – 395 007, Gujarat, India

Statistical Process Control in Pharmaceutical Industry: A Case Study for

ABSTRACT

In this paper we would like to investigate the work done in the tablet manufacturing plant and it aims at finding the best and
most suitable and efficient way of using man, machine, material, money. In this paper only tablet section are considered for
analysis change in plant layout reduces the distance travels two third of previous one. Introduction of one new mixer is found
to substantially increase of production. It results increase in productivity.

Keywords: Plant layout,

INTRODUCTION

The application of work study in tablet manufacturing is to investigate the work done in the tablet manufacturing plant and it
aims at finding the best and most suitable and efficient way of using resources i.e. men, material, machine, money. Every
organization tries to achieve best quality production in the minimum possible time. The time required to manufacture the
tablet depends upon manufacturing procedure, which involves, list time and don’t cause fatigue to the worker. The main aim
of this paper is to improve the productivity of the industry.

MANUFACTURING
In the tablet-pressing process, it is important that all ingredients be dry, powdered, and of uniform grain size as much as
possible. The main guideline in manufacture is to ensure that the appropriate amount of active ingredient is equal in each
tablet so ingredients should be well mixed. Compressed tablets are exerted to great pressure in order to compact the material.
If a sufficiently homogenous mix of the components cannot be obtained with simple mixing, the ingredients must be
granulated prior to compression to assure an even distribution of the active compound in the final tablet. Two basic
techniques are used to prepare powders for granulation into a tablet: wet granulation and dry granulation. Powders that can be
mixed well and therefore do not require granulation can be compressed in to tablet through Direct Compression.
 Proc. of the 1st International Conference on Modern Trends in Industrial Engineering, November 17-19, 2011

S.V. National Institute of Technology, Surat – 395 007, Gujarat, India

Fig. 1 Simplified Process Control Flow Chart for Tablet Manufacturing

ACCESSIBLE EXERTION
The existing method of the tablet section has described in the fig-2 .It shows that the raw material moves from raw material
store to the Blender, which is 11 meter far. From the raw material store. In the Blender the blending process complete within
15 minute and after that the material moves from Blender to Mixer, which is 1.5 meter from the Blender. Here the mixing
process complete within 15 min and after that material moves from Mixer to Dryer, which are 1.5meter far from the Mixer.
Now the Dryer process complete in Dryer within 2hour and after that the material moves from Dryer to Dry Granulation
which is 8meter far from the Dryer. Here Granulation process complete within 15minute. and after that the material again
move to the Mixer, which is 3meter far from the Dry Granulation. The mixing process complete in Mixer within 15 minute
and after that material move Mixer to Tablet Compression, which is 8mter from Mixer. Here the Compression process
complete within 15 minute and after that material move from Tablet Compression to the Organic Film Coating, which is
03meter. Far from the tablet compression. This is the end of process of the manufacture of the tablet.
 Proc. of the 1st International Conference on Modern Trends in Industrial Engineering, November 17-19, 2011

S.V. National Institute of Technology, Surat – 395 007, Gujarat, India

Fig.2 The Flow Diagram of Tablet Section.

Fig.3 The Existing Plant Layout Of H.O.D Lab Ltd. Fig.4 Flow Process Chart–Material Type Tablet Process

ANALYSIS
 Proc. of the 1st International Conference on Modern Trends in Industrial Engineering, November 17-19, 2011

S.V. National Institute of Technology, Surat – 395 007, Gujarat, India

In the existing process only one mixer is use and the bottleneck problem is occur due to the twice of flow of material in the
mixer, and the distance moving long. Fig 5 is the proposed method, which eliminates all the difficulties, which is, occurs in
the existing process. Here two mixer use in the place of one mixer of the same capacity and also reduced the distance moved
by the material. In this method the raw material moves from the raw material store to the Blender, which is 5 meter far from
the Raw Material Store. In the Blender the blending process complete within 15min, and after that the material moves from
Blender to Mixer, which is 1.5 meter away from the Blender. Here the mixing process complete within 15 minute and after
that material moves from Mixer to Dryer, which is 1.5meter away from the Mixer. Now the material move from Dryer to Dry
granulation, which is 3 meter far from the dryer. Here Granulation process complete within 15min and after that material
move from dries Granulation to new mixer, which is 3 meter far from the Dry Granulation. Here again the mixing process
complete within 15 minute and after that material moves from New Mixer to Tablet Compression, which is 3 meter far from
the New Mixer. Here the Compression process complete within 15 minute and after that material move from Tablet
Compression to the Organic Film Coating, which is 3meter far from the tablet compression. This is the end of proposed
method of manufacture of the tablet.

Fig.5 Proposed Flow Diagram of Tablet Section

S.V. National Institute of Technology, Surat – 395 007, Gujarat, India

Fig.6 Recommended Plant Layout for H.O.D Lab Ltd. Fig.7 Flow Process Chart–Material Type Tablet Process

DISCUSSION
Investigation of manufacturing process, transportation and lay out of a pharmaceutical company has been carried out with
help of Method study, a industrial engineering tool to find out the effect of these factors on production capacity and
production cost. Investigation is also aims to find out the bottlenecks in operation and subsequent Elimination of these. The
pharmaceutical company considered is manufacturing tablets.. Analysis gives the effect of plant layout on distance traveled
and sequencing of machines.

RESULTS
The following conclusions can be drawn from the results
1. Change in plant layout reduces the distance, in existing layout distance traveled is 61 meter and it is reduced to 45
with recommended layout i.e. reduction in floor transportation is16 meter.

2. Installation of one additional mixer would result in increase of production capacity.

3. In the existing set up manpower remains idle for half of their working hours. By making the change in machine
layout and installing one additional mixer this idle time would be eliminated and production would be nearly
twofold.
 Proc. of the 1st International Conference on Modern Trends in Industrial Engineering, November 17-19, 2011

S.V. National Institute of Technology, Surat – 395 007, Gujarat, India

4. The MRP of product is 0.75Rs. Per tablet and production cost is 0.25 Rs. How much company get is not exactly
known because company doesn’t disclose it. But one can understand this profit percentage can be reasoned for cost
of mixer machine.

CONCLUSION
An application of work study in tablet manufacturing is to investigate the work done in the tablet manufacturing plant and it
aims at finding the best and most suitable and efficient way of using resources i.e. men, material, machine, money the present
studies involve the operation analysis and the effect of plant layout and line balancing on the production and cost of the
product. Modification in layout of machines results in elimination of unproductive movement of worker and line balancing of
machines results in increase in production capacity of plant these modifications yields in low production cost i.e. economical
manufacturing of product. Capacity of tablet compression machine is seventy-five thousands per hour. In existing set up its
only 1/3 capacity i.e. twenty-five thousands per hours is being used. By implementing our recommendations it would go up
to fifty thousand per hour. But its capacity is not still exhausted. It can be considered for future work.

REFERENCES
(1) Banker, R. D., Field, J. M., Schroeder, R. G. and Sinha, K. K., Aug.1996,“Impact of Work Teams on Manufacturing
Performance: A Longitudinal Field Study”, The Academy of Management Journal, Vol. 39, No. 4 , pp. 867-890.

(2) Bertrand, J. W. M.,Fransoo, J. C., March 2002, “Operations management research methodologies using quantitative
modeling”, International Journal of Operations & Production Management, pp 241 – 264.

(3) Lawrence, S., Simon, F., Phil, T., lan, M., April 1998, “Work shift duration: a review comparing eight hour and 12
hour shift systems”, Occupational & Environmental Medicine. 55(4), pp 217-229.