Analysis and optimization of a cosmetic production department with focus on GMP and safety compliance

This thesis presents a study aimed at improving operational efficiency and safety within the bulk manufacturing department of a cosmetics production facility, with a particular focus on the weighing room. The research began with the identification of critical issues through internal GMP audits, direct observations, and analysis of process data. These methods revealed numerous inefficiencies, including high levels of non–value-added time and recurring non-conformities related to material handling and layout. To address these challenges, a series of corrective actions were implemented, centered on the redesign of the weighing room layout. The intervention included the reorganization of equipment and material storage, the separation of clean and dirty areas and enhanced operator training. These changes were designed to align operations more closely with Good Manufacturing Practices (GMP) and improve production flow. In parallel, a fire load analysis was conducted to assess the fire risk associated with the storage of combustible materials. By identifying high-impact materials, such as fats and paper-based packaging, and relocating them to safer storage areas, the specific fire load was significantly reduced. The implementation of a just-in-time approach to raw material stocking further contributed to fire risk mitigation. The results of the project demonstrated clear improvements in GMP compliance, operational efficiency, and fire safety. This work highlights the importance of combining layout design, risk management, and regulatory adherence in achieving sustainable improvements in manufacturing environments