Inbound process optimisation of a distribution centre : a GSK Vaccines case study

Details

Supervisors

Chevalier, Philippe

Faculty

Louvain School of Management

Degree label

Master [120] en ingénieur de gestion

Abstract

Among the pharmaceutical companies, GSK is one of the leaders on vaccine market. In 2018, GSK distributed 700 million of doses all over the world. GSK expectation was to increase this target in the coming years to remain competitive and meet medical needs. In 2019, 60 to 80% of vaccine doses were transiting by the GSK warehouse distribution excellence (WADE) centre located in Gembloux and were sent from different production sites on pallets. The processes were limiting to reach GSK vaccine doses distribution ambition. The aim of this project-thesis was therefore to evaluate opportunities for process optimization in WADE with a specific focus on inbound process flows, and to prepare recommendations for increasing process efficiency by at least 10%. DMAIC methodology, recognised in the literature as a successful approach for such optimiza- tion initiatives, has been applied to this project. In the “Define” phase, 16 inbound process flows have initially been mapped, considering different types of material as well as different storage temperature and production site. Among them, the 7 flows used in routine have been selected to enter in “Measure” “Analyse” phases. A measurement system has been designed to collect specific inbound process parameters and to run deeper analysis. Out of the 7, the four most impactful flows on GSK business in terms of volumes have finally be kept for identification of opportunities for improvement in the “Improve” phase of the project. Drivers leading to waste of time have been clearly identified for the 4 selected flows. For each driver, alternative ways of working have been elaborated, prioritised based on implementation feasibility / value adding potential and have been articulated around two scenarios: (1) a “best case scenario” with a high improvement potential (70% increase of inbound process efficiency) but more difficult to implement and (2) a “most realistic case scenario” easier to implement but with a lower improvement potential (30% increase of inbound process efficiency). GSK decided to launch an improvement plan based on recommendations provided through this project. The plan has been launched in May 2019 and the first results were encouraging. The conclusion is that the objective of this project-thesis has been met. The results have even exceeded GSK expectations.