Company
Novozymes S/A is the biotech-based world leader in biological solutions employing over 3,000 employees worldwide for more than 30 years. Their subsidiary Novozymes Biologicals, Inc. (NZB) in Salem, VA, maintains facilities for manufacturing, research & development, & commercial management. NZB products are used in wastewater treatment, bioremediation, institutional and household cleaning, and agricultural applications. This facility houses over 40,000 square feet of manufacturing and employs over 75 workers.

Situation
Novozymes' own management team realized that operations were plagued with waste and non-value added activities. Some of the immediate concerns were inefficient plant layout, inadequate space, poor workflow, long lead times, and stagnant inventory just to name a few.

Response
VPMEP recommended the identification of two key teams to develop improvement action plans, and follow through on the implementation of the action plans. The Steering Team guided the organizational effectiveness assessment process and later reviewed the results. The Dry Production Process Improvement Team mapped the process flow and identified opportunities to eliminate waste. A Lean 101 workshop was conducted for all team members. Key plant personnel learned to establish basic lean and high performance principles. VPMEP then conducted organizational effectiveness assessments of process flow, job design, training procedures, and other human resource practices. Employee involvement was an integral part of the assessment process as subject matter experts and contributors. Following the assessments, VPMEP produced a final report and proposed an action plan for improvements.

Results
Significant financial benefits as a result of the Dry Production Process Improvement Team implementation were in the following areas the first year of the project:
• 75% reduction in over time,
• 30% increase in inventory turns,
• 45% reduction in late deliveries.

Testimonial
"As a global business and market leader in our industry, the need to continuously improve key performance metrics is critical to maintaining a competitive edge. VPMEP’s project managers provided the tools and facilitation skills necessary to evaluate process flow and eliminate waste. VPMEP’s service enabled us to build internal capacity and ownership of the process, supporting continuous improvements." –Randy Palmer, Plant Manager, Novozymes Biologicals, Inc.

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