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Real Lean Transformation in a Biopharmaceutical R&D Facility

Client situation & approach

A leading pharma company engaged us to increase project workload capacity at their R&D facility whilst improving the schedule adherence of current project workloads. Advanced bioreactor labs utilization was optimized at a site responsible for the development of the next gener­ation of biological derived drugs, including one $6 billion/year blockbuster

  • Robust capacity planning process for all projects that maximized equipment utilization and let scientists focus on scientific innovation (NVA tasks minimized)
  • Rhythm wheel levelling strategy for preculture processes
  • Established standard work practices for the sampling and analysis of results
  • Electronic visual management system to monitor projects progress and report instructive KPIs


  • Optimized utilization of advanced bioreactor labs by 29% with significant downtime reduction thanks to new planning and re-engineered changeover processes