Our client is leading multinational pharmaceutical company headquartered in Germany, operating on a global scale with 146 affiliates and a workforce of over 47,000 employees.
Business Challenge
The customer faced the challenge of implementing Lean and Operational Excellence best practices across more than 40 labs and QA functions. This involved optimizing operational efficiency to achieve short and consistent lead-time performance, thereby improving batch release and R&D project lead-times and consistency. Additionally, it aimed to enhance the sites' ability to make and meet accurate commitment dates for clients.
Approach
EFESO supported in:
- Design and Implementation of Levelling, Flow and Standard Work solutions for each Lab & QA group
- Development of Capacity and Demand planning tools to enable accurate commitment dates for commercial project work
- Implementation of effective Short Interval Control & Performance Management processes in each group
- Design and implementation of digital lab & group management tools
Main Results
- Achieved 10-36% productivity and capacity increases across more than 40 labs and QA groups.
- Realized 30-70% increases in the percentage of routine batches released on-time and adherence to commitment dates for commercial project work.
- Achieved 10-75% reductions in routine testing lead-times.
- The site also took on global raw material testing workloads with no increase in overall resourcing.
