As a global leader in the pharmaceutical industry, Eli Lilly is committed to innovation, precision, and high-quality standards. To maintain these standards, Eli Lilly’s maintenance team needed reliable tools to support their productivity goals, meet strict cleanroom requirements, and seamlessly integrate with their 5S lean manufacturing program. By partnering with Sonic Tools, Eli Lilly has experienced notable gains in organization, inventory control, and overall productivity.
Improving Asset Management and Reducing Tool Loss
In high-stakes manufacturing, efficiency and quality control are essential. For Robert Way, Sr. Lead Technician-Maintenance at Eli Lilly, the Sonic Foam System has been pivotal for his team of technicians in upholding 5S principles and cleanroom standards. The 5S methodology ensures that every tool has a designated place, creating a clutter-free, organized workspace—a critical factor in cleanrooms, where organization reduces contamination risks and safeguards product quality. With tools organized and easily accessible, Robert’s team avoids time lost to searching for misplaced items, helping to maintain the importance of the 5S lean manufacturing protocols and asset management in his facility.
The Sonic Foam System also enhances asset management by offering real-time visibility of each tool’s location, critical for teams sharing toolboxes. This organizational system has significantly reduced tool loss and replacement costs, saving time and labor. According to Robert, the Sonic Foam System has improved his team’s productivity by nearly 50%—a significant boost in a high-demand environment. “In a production environment, each minute of downtime can cost $10,000. Saving even 15 minutes equates to tens of thousands of dollars,” he adds, emphasizing the efficiency gains Sonic Tools has brought to Eli Lilly’s maintenance team.
A 5S Lean Approach to Organization
The 5S program is a foundational lean manufacturing approach focused on organization, cleanliness, and efficiency—core principles in high-stakes environments like pharmaceutical manufacturing. For Eli Lilly, 5S aims to streamline operations, reduce downtime, and promote safety through organized, accessible tools and equipment. In an industry where every minute of downtime impacts productivity and profits, these principles are crucial.
“As a pharmaceutical company, we prioritize cleanroom standards and 5S lean principles. Tools and toolboxes must be clean and wiped down multiple times a week, and Sonic Tools make this process much easier,” Robert explains.
Sonic Tools has been instrumental in Eli Lilly’s 5S efforts, equipping their team with toolboxes and tools optimized for organization. Each tool now has a designated spot within the Sonic Foam System, supported by inventory lists and visual guides. Technicians can locate the tools they need instantly, maintain accountability, and avoid wasted time searching for misplaced items.
The Sonic Foam System has also helped Eli Lilly structure tool storage by ensuring each tool has a dedicated slot, reducing the risk of tool loss or misplacement. This level of organization aids in asset management, allowing better inventory tracking, which is especially valuable during audits.
“Auditors appreciate the clean, well-organized workspaces made possible by Sonic’s products,” says Robert, a reflection of Eli Lilly’s commitment to lean principles.
Additionally, each toolbox and tool are clearly labeled with a checklist that team members complete at the end of each shift. This simple practice makes it easy to identify missing tools, boosting accountability and encouraging responsibility over shared resources. The result is a streamlined process that minimizes interruptions, keeps work areas orderly, and most importantly, helps Eli Lilly maintain a consistent workflow.
Streamlined Solutions: How Sonic Tools Supports Eli Lilly’s Maintenance Team
One of the standout benefits for Robert has been Sonic’s commitment to direct communication and customer service. Robert explains how in the past, navigating multiple customer service and sales representatives added unnecessary complexity, leading to delays and miscommunication. Now, with Sonic, Robert has a dedicated point of contact who understands his team’s needs, making each interaction clear and efficient. This single-source approach has simplified the purchasing process and allowed him to devote more time to his work.
Additionally, the pre-etched tools from Sonic have also transformed Eli Lilly’s inventory process. Previously, Robert’s team had to send tools to a central shop for etching—a costly and time-consuming step. With Sonic’s advanced etching capabilities, this extra step is eliminated, saving both time and money. Now Sonic tools are ready for immediate use upon arrival, enhancing efficiency for those team of technicians.
Looking Ahead
Robert plans to equip new line mechanics on his team with pre-filled, etched-tool backpacks, increasing accountability and productivity across the team. He values the transformative impact Sonic Tools has had on Eli Lilly’s workflow. From excellent customer service to the Sonic Foam System and pre-etched tools, Sonic has helped Eli Lilly’s maintenance team achieve new levels of productivity, asset management, and maintain critical inventory standards. In a pharmaceutical environment where every second counts, Sonic Tools has proven to be a valuable partner.
