~500
Employees
Biotech Program Cuts Lead Time 60% and Inventory 45%
A global biotechnology company partnered with EFESO to reduce lead times and optimize inventory across Quality, Manufacturing, and CDMO operations. By leveraging cross-functional collaboration, detailed process mapping, and data-driven recommendations, the program achieved significant reductions in batch record lead times, inventory levels, and stock obsolescence risk.
Life Sciences
Manufacturing
Operations Strategy and Transformation
Supply Chain
Our Client
The client is a global biotechnology company dedicated to the research, development, and commercialization of therapies for rare and severe diseases. With a strong focus on patient-centered innovation, the organization operates at the forefront of advanced biologic and genetic treatments.
+500M
Annual revenue
+20
Countries in global footprint
The Challenge
Our client’s contract manufactured supply chain had long E2E lead times of between 18-24 months and was holding significant volumes of inventory. Our client was in the early stages of a new product launch and were anticipating volumes to ramp up considerably in the near term. EFESO were asked to understand and resolve the performance shortfalls in the existing supply chain and ensure the future supply chain is designed to minimize lead time and inventory.
Key challenges navigated while delivering the project include:
- Cross-functional engagement: Varying levels of involvement from different departments.
- Team availability: High BAU pressure in a New Product Introduction (NPI) environment.
- Change management: CDMO commitment to other clients limited flexibility to adopt new processes.
Real Results Achieved Together
The EFESO-led program enabled the client to achieve measurable improvements in lead times, inventory levels, and stock risk management, while fostering cross-functional collaboration.
-60%
Reduction in lead time
-45%
Inventory reduction
$9M
Risk of stock obsolescence mitigated
Transformation Impact
- Streamlined batch record processes to accelerate production.
- Reduced inventory, improving working capital efficiency.
- Established a collaborative and data-driven approach across Quality, Manufacturing, and CDMO teams.
- Embedded processes to mitigate stock obsolescence risk.
Our Approach
EFESO implemented a structured program combining human dynamics, data analysis, and operational process mapping to enable sustainable improvements.
- People and Engagement
• Clarified project purpose and benefits for all stakeholders to secure buy-in.
• Applied Human Dynamics methodology to ensure collaborative behavior. - Data-Driven Insights
• Performed detailed analysis to identify performance gaps and opportunities.
• Recommendations were evidence-based, minimizing subjective debate. - Process Mapping and Solution Design
• Mapped existing processes at an operational level for a clear understanding.
• Developed tailored, win-win solutions through cross-functional workshops. - Program Governance
• Ensured senior management commitment and active support.
• Project duration: 1.5 years, maintaining focus on deliverables despite BAU pressures.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
Ready to Transform Your Supply Chain Performance?
- Slash lead times and free up working capital trapped in excess inventory
- Stop struggling with long cycle times that prevent you from responding to market demands
- Join biotechnology leaders who’ve achieved breakthrough improvements in supply chain agility
Discover More Clients Results
Consumer Goods and Luxury
A leading bicycle manufacturer's shift from a supplier-driven model to a customer-centric operating model.
45K m²
Optimized factory layout (reduced from 52K m²)
Industrial Manufacturing
Creating a solid, structured plan for the material flow of its production and validated the static forecast, enabling the factory to increase the output with the existing machinery.
13%
Reduction in release time for high-value APIs
Chemicals
Life Sciences
A QC lab optimization framework helps a multinational chemical-pharmaceutical company achieved simultaneous gains in productivity, service level, and resource efficiency, delivering measurable improvements in release time, productivity, and FTE requirements without compromising quality.
+25
Business cases initially identified
Consumer Goods and Luxury
Design and implementation of a 10-year strategy targeting 4% annual growth for a world-leading luxury group, focused on aligning operations.
12
"Golden Rules" implemented for production planning
Industrial Manufacturing
Creating a solid, structured plan for the material flow of its production and validated the static forecast, enabling the factory to increase the output with the existing machinery.
+10K
Pallet positions created through optimized DC layout expansion design
Life Sciences
EFESO conducted a feasibility study for a new 10,000-pallet automated warehouse in Romania, optimizing logistics design, layout, and CAPEX to enable scalable, efficient pharmaceutical distribution.
Industrial Manufacturing
Fact-based restructuring of a complex industrial site, enabling a clear shutdown decision, cash-drain elimination, and a structured roadmap for execution.
40%
Reduction in Capital Expenditures for new production technology
Packaging
A leading global manufacturer of glass containers reduce capital expenditure by 40% in the commercialization of a new glass production technology by applying Value Engineering and Lean Product Development principles.