12
Batches per day capacity
Significant Capacity Improvement at Cell Therapy Site
A major pharmaceutical company wanted to significantly ramp-up volumes at one of its Car-T Cell Therapy facilities, without a proportional increase in staff. Together, we analyzed each lab test and developed detailed standard work and scheduling processes to maximize their productivity. This operational transformation enabled the site to triple the number of batches with its existing team structures.
Industry: Life Sciences
Service: Manufacturing
Service: Operations Strategy and Transformation
Our Client
The company operates advanced cell therapy and Biotechnology facilities requiring complex Biotech, Microbiology and various cell therapy assays. Its operations demand precise coordination across multiple testing protocols while adhering to stringent pharmaceutical quality standards.
24
FTEs for full operation
4-day
10-hour shift pattern
“"The results were transformative for our business."
“
The Challenge
The microbiology lab faced a critical operational constraint as batch volumes were set to increase significantly.
- Scaling without proportional hiring – The site needed to accommodate substantial batch volume growth but wanted to avoid hiring large numbers of additional staff to manage the increased workload
- Complex testing coordination – Multiple test types including required careful scheduling and resource allocation across different roles and timeframes
- Inefficient capacity utilization – Staff moved ad hoc between tasks with large portions of the day underutilized, while the four-day, 10-hour shift pattern created uneven resource-load distribution
Real Results Achieved Together
The lab transformation fundamentally changed how the facility manages its testing capacity and staff productivity. Working alongside in-house teams we created a scalable operational model that dramatically improved throughput without additional headcount.
+94%
Productivity improvement (12 batches/day)
+146%
Productivity increase (24 batches/day)
1.8→3.5
Batches per person per day
Transformation Impact
- Enabled significant scale-up of operations without increasing headcount
- Delivered what the client called "transformative" results for its business
- Achieved exceptional productivity gains well above typical project increases
Our Approach
We began by analyzing every test performed and developing detailed standard work for each process.
For each test, we outlined all required activities, determining maximum samples per run and mapping each process step along with the time requirements and whether that time was hands-on occupied or unoccupied time.
Our focus centered on optimizing how different tests could be combined within staff roles – pairing suitable tests together to make a good use of analyst time and integrating tests with non-test tasks.
Everything was then integrated into a “rhythm wheel”, which schedules all the routine work in a set pattern. This comprehensive approach ensured that staff time was fully utilized rather than having people move ad hoc between tasks.
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Facing Similar Pharmaceutical Operations Challenges?
- Struggling to scale production without large headcount increases
- Ready to transform underutilized capacity into measurable productivity gains
- Let’s explore how operational excellence can unlock your facility’s potential
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