Case study · Batch records
Simplified, managed records: up to 50% shorter throughput time in 8 months
On this sterile dosage site, batch records took too long to get from production to release. We combined record simplification with visual management of their progress.
The results
−30 to −50%batch record throughput timeafter 8 months
3production units managed
4records coached, then rolled out by the site
8 monthsto achieve the result
The starting point
- A sterile liquid dosage production site of about 300 people.
- Batch records that stayed a long time between the end of production and release.
- No shared view of where each record was.
What we did together
- Analyse the recordEach data item screened with our C.O.B.R.A. tool (13 questions), and the structure compared with the actual sequence on the shop floor.
- We do it for youA first prototype built with the team, following our 11 ergonomic principles, then tested in production.
- You do it, we coachThe site’s teams design the following records, with our support at each step.
- Manage the recordsA ritual and a visual board in 3 production units, to follow each record through to release.
- You roll it outThe site extends the approach to its other records, with regular support sessions.
What made the difference
Fewer errors
simplified records, so fewer corrections and less back-and-forth.
A shared view
everyone knows where each record stands.
Blockers removed quickly
the regular check-in moves waiting records forward.
An autonomous site
4 records coached, the rest rolled out by the teams.
Our takeaways
Simplifying the record reduces corrections; managing its journey reduces waiting. It’s the combination of both that really shortens throughput time.
The approaches used
Our advice if you’re getting started
- Don’t just simplify the record: manage its journey to release too.
- Make each record’s progress visible: waiting becomes obvious.
Do your batch records always come back with corrections?
Let’s talk about your records: together we’ll analyse a typical record and what it costs you in review.