Lean Roadmap

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Lean Roadmap

• John Earley
• Head of Lean AstraZeneca, Operations

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Discussion Points

• AstraZeneca Overview
• History of Lean in AstraZeneca
• More than Lean Manufacturing
• Key Challenges
• QA

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AstraZeneca Operations Overview

• One of the worlds leading pharmaceutical
  companies.
• A 70-year track record of new medicine
  innovation.
• Active in over 100 countries
• Over 60,000 employees 18 in the UK, 21 in
  Sweden, 20 in the US, 41 in the rest of the
  world.
• 16 research centres in 8 countries.
• 24 manufacturing sites in 17 countries with
  over 13,000 people.
• Excludes MedImmune

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History of Lean at AstraZeneca
Birth of the AZSS
First pilots of Lean in Operations
DDS With Customers and Suppliers
Operations Wide Programme
2008
2000
2001
2002
2003
2004
2005
2006
2007
Lean / Six Sigma Takes Hold in RD
Demand Driven Supply in Sites
Integrated AZ Wide Lean/Sigma?
First Pilots of Lean / Six Sigma in RD
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Pharma industry in context
Did you know ..?
Can all of this be due to the regulatory
environment or is our approach also a cause?
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The Drivers for Lean
The Path to Long-term Health
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More Than Lean Manufacturing
Detail
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Sustaining the ChangeLean maturity profile
Level 1 2 3 4 5
Capability Systems Process Org People Lea
dership
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Its All About The People

• Process issues
• Physical changes
• Capability

• Esteem issues
• My status
• My value
• My power

• Emotional issues
• My job
• My pay
• Can I do it?
• My community

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Transformation Vs. Incremental
Results
Time
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QA
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Organizational Model
Focus on Current Goals 100 Execution Measured
on achievement of current targets
Process Owner
Focus on Current Goals 100 Execution Measured
on achievement of current targets
Finance
QA/Compliance
BU 1
HR/SHE
Support Needs
Process Execution Team Leader
QA/QC
Scheduling/ MM
Tech Services
Process Facilitator
Maintenance
Operators
Coach
Project/Facilities Engineering
Support Services
IT
BU 2
New Tech PE Group
Process Execution Team Leader
QA/QC
Scheduling/ MM
Tech Services
Process Facilitator
Maintenance
Operators
Coach
New Technologies Process Excellence Group New
technologies, practices processes New target
setting Process Excellence (OEE, DDS, SPC, 6
Sigma, etc.) Intellectual Property Knowledge
Transfer Repository
Functional Shared Services
Focus on policy, shared services projects
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Organisation Design Approach

• Return

• Guiding principles agreed by central leadership