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Lean Laboratory project in a leading R&D pharmaceutical company gains a 29% increase in capacity

Client situation & approach

A leading pharmaceutical company engaged us to increase project workload capacity at their R&D facility. The site was responsible for the development of the next generation of biological derived drugs, including a $6 billion/year blockbuster.

EFESO supported by:

  • Optimizing the utilization of the Advanced bioreactor lab at the same time as improving the schedule adherence of current project workloads.
  • Improving the robustness of the capacity planning process for all projects that maximized equipment utilization and allowed scientists to focus on scientific innovation thus minimizing Non Value Added tasks.
  • Implementing a rhythm wheel levelling strategy for the preculture processes
  • Establishing standard work practices for sampling and the analysis of results


  • 29% increase in utilization of advanced bioreactor labs
  • Implementation of a new optimized planning process
  • Significant reduction in downtime due to enhanced planning and re-engineered changeover processes
  • Implementation of an electronic visual management system to plan and monitor project progress and report instructive KPIs