$6B
Annual blockbuster drug revenue
Lean Lab Transformation Boosts R&D Capacity by 29% in Pharma
A leading pharmaceutical company partnered with EFESO to increase workload capacity at its R&D facility while maintaining schedule adherence for ongoing projects. Through Lean Lab methodologies and optimized planning, the client achieved significant gains in lab utilization and operational efficiency without additional resources.
Industry: Life Sciences
Service: Lean Lab
Service: People and Organization
Our Client
The client is a leading pharmaceutical company whose R&D facility is responsible for developing the next generation of biologically derived drugs, including a $6 billion-per-year blockbuster. The site’s advanced bioreactor lab required optimization to unlock additional capacity and support accelerated innovation.
The Challenge
The client needed to increase project workload capacity at their Research & Development (R&D) facility while maintaining schedule adherence for current project workloads.
The project aimed to optimize and increase the utilization of advanced bioreactor laboratories at a site responsible for developing the next generation analogues of a portfolio of biologically derived (large molecule) drugs.
Real Results Achieved Together
Through the implementation of lean laboratory methodologies and optimized planning processes, the pharmaceutical R&D facility achieved significant improvements in capacity utilization and operational efficiency.
+29%
Increase in advanced bioreactor lab utilization
Transformation Impact
- A robust capacity planning process maximized equipment utilization, freeing scientists to focus on innovation while minimizing time spent on non-value-added activities.
- A standard rhythm wheel leveling strategy, visual management systems, and structured workflows further strengthened consistency and performance.
- Significant reduction in downtime due to enhanced planning and re-engineered changeover processes
- Marked increase in overall project workload capacity without additional equipment or scientist resourcing
Our Approach
EFESO supported the transformation by:
- Optimizing the utilization of the advanced bioreactor lab while improving the schedule adherence of current project workloads.
- Strengthening the robustness of the capacity planning process for all projects to maximize equipment utilization and allow scientists to focus on scientific innovation.
- Implementing a rhythm wheel leveling strategy for the preculture processes.
- Establishing standard work practices for sampling and the analysis of results.
- Introducing an electronic visual management system to plan, monitor project progress, and report instructive KPIs.
Related Services
Lean Lab
Volatile workloads create productivity troughs and lead-time peaks. We stabilize lab operations through capacity modeling, dynamic resource allocation, and lean process optimization.
People and Organization
Workforce transformation, leadership development, and structure optimization. Learn more about our People & Organization consulting services.
Ready to Unlock Hidden Capacity in Your R&D Operations?
- Transform your lab into a high-performing innovation engine that delivers more breakthroughs with existing resources
- Stop losing valuable research time to inefficient planning and equipment bottlenecks
- Join pharmaceutical leaders who’ve achieved double-digit capacity gains without adding headcount
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