Background
A global leader in bioscience, advanced pharmaceutical products, equipment and consumables, chemistry, and biotechnology. With a staggering billions of dollars in revenue and a workforce of thousands of employees, this industry giant embarked on a substantial strategic investment project to meet the rising demand for gene therapy and pharmaceutical products. This included a millions of dollars investment in pharmaceuticals site with six new clean room suits and over another over hundred million dollars investment in a bioscience products site with eleven new suits.
Challenges
➢ The demand for gene therapy and pharmaceutical products was expected to surge, necessitating the expansion of production facilities.
➢ Existing clean room suits were outdated and did not comply with current regulatory standards, posing a risk to product quality and safety.
➢ The current capacity was insufficient to meet the anticipated production volumes.
➢ The infrastructure was inadequate to support the specialized equipment and processes required for modern manufacturing.
➢ There was a significant risk of production delays, regulatory issues, and compromised product integrity without adequate investment in facility upgrades and expansion.
Implementation
➢ Project Management: Initiation through Operational Readiness effective project management steps implementation.
➢ Value Stream Mapping: Major Products Value Stream Maps to identify waste (Muda), long processing times, bottlenecks, and capacity constraints.
➢ Equipment Assessment: Evaluation of the advantages and disadvantages of current equipment and identified new equipment types and efficient process designs for shorter lead times.
➢ Design for Six Sigma (DFSS): Integration of the DFSS concept to ensure high-quality products and services designed right the first time, leading to improved customer satisfaction and reduced costs.
➢ Layout Optimization: Working with local teams to optimize the layouts of support units, warehouses, and departments.
➢ On-Time Project Closure: Timely closure of projects and the successful startup of the new sites.
Results
The implementation of these strategies led to significant improvements:
➢ Project On-Time Closure: 95% On Time Completion and Start-Up
➢ Process Time Reduction: Process times were reduced by 10% to 20%, enhancing overall efficiency.
➢ Improved Safety and Ergonomics: Safety standards and ergonomics were improved, creating a better working environment.
➢ Balanced Processes: We achieved balanced processes and high equipment utilization, optimizing production capacity.
Testimonials
“Our operational excellence journey reached new heights. The team’s expertise in Lean methodologies and Six Sigma tools resulted in substantial cost savings, improved efficiency, and enhanced safety standards across multiple manufacturing sites. Their efforts truly embody the spirit of continuous improvement.” – Vice President, Manufacturing
“Everyone waited for new therapies and products to be available for a long time, and we owe today’s success to those hard-working teams.” – North American Sales Leader
