Case Study 1 –
Pharmaceutical / Nutraceutical Industry – Process Improvement & Lean Optimization
Client Background: A leading nutraceutical manufacturer producing tablets and powders faced recurring line inefficiencies, frequent equipment stoppages, and inconsistent batch yields across blending and filling sections.
Challenge:
- Variation in batch cycle time across shifts (up to 25%).
- High in-process rejection (2.5–3%) due to powder segregation and underfilling.
- Manual material movement and poor visibility of production losses.
Sava Solutions Approach:
- Conducted a Lean process mapping (VSM) across granulation, blending, and filling lines.
- Implemented process parameter standardization using DoE (Design of Experiments).
- Introduced visual production control and digital OEE dashboards for operators and supervisors.
- Reorganized layout for unidirectional material flow and minimized cross-contamination risk.
- Trained line teams in root cause analysis (RCA) and quick changeover techniques (SMED).
Outcome:
- Cycle time reduced by 18%, improving daily output capacity.
- In-process rejections reduced from 2.8% to 0.9%.
- Batch release time shortened by 12 hours due to faster QA clearance.
- Improved operator engagement and ownership of process parameters.
Impact:
The plant achieved a consistent, audit-ready operation with improved compliance, productivity, and operator efficiency — all within three months of implementation.
Case Study 2 –
FMCG / Food Processing – Supplier Assessment & Capability Development
Client Background: A well-known FMCG company relied on multiple regional vendors for primary and secondary packaging materials. Quality issues such as print mismatch, contamination, and delayed deliveries affected packaging line efficiency.
Challenge:
- Frequent packaging rejections and last-minute supplier substitutions.
- Non-standard quality control systems across vendors.
- Poor visibility of supplier performance metrics.
Sava Solutions Approach:
- Conducted supplier audits for 15 key vendors using a structured QMS, HSE, and GMP-based checklist.
- Established a Supplier Evaluation Scorecard (Quality, Delivery, Cost, Compliance).
- Organized vendor capability workshops on quality systems, traceability, and hygiene standards.
- Created a Vendor Improvement Tracker (VIT) monitored quarterly with the client’s procurement and QA teams.
Outcome:
- Supplier non-conformities reduced by 60% in six months.
- 95% on-time delivery adherence achieved.
- 100% vendor compliance to hygiene and labeling standards during external audit.
- Strengthened buyer–supplier collaboration and reduced firefighting.
Impact:
The client institutionalized a transparent supplier management framework — transforming audits into a continuous improvement tool.
Key Takeaways
- Pharma/Nutra: Process reliability and quality built into every batch.
- FMCG: Stronger supplier ecosystem delivering consistency and compliance.
- Across Sectors: Sava Solutions integrates Lean, QMS, and data-driven improvement to create sustainable manufacturing excellence.
Sava Solutions – Building High-Performance Manufacturing Ecosystems.