$5.5M
EBITDA Savings
Building Continuous Improvement Across Sites in Pharma CDMO: $5.5M EBITDA Savings and 42% Reduction in Equipment Downtime Through a Unified Continuous Improvement Program
Industry: Life Sciences
Service: Lean Lab
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
Pharmaceutical contract developer and manufacturer operating six production sites across two countries.
The Challenge
Following multiple mergers, the company faced operational inefficiencies and cultural misalignment across its six sites:
- Inconsistent performance and process variability reducing margins
- Downtime limiting throughput and efficiency
- Lack of a standardized Continuous Improvement framework
- Inefficient production, laboratory, and office processes
- Complex and resource-intensive regulatory documentation (ANSM, FDA, ANVISA)
Real Results Achieved Together
Through a unified continuous improvement strategy and structured performance governance, EFESO enabled the client to drive measurable gains across production and laboratory operations.
22%
Improvement in OEE
30%
Increase in Labor Productivity
42%
Reduction in equipment downtime
Transformation Impact
- 3-to-1 Consolidation in Laboratory Operations
- Increased production capacity and overall efficiency
- Strengthened process discipline and standardization across all sites
- Embedded a sustainable culture of accountability and continuous improvement
Our Approach
EFESO supported the client through a structured, multi-site Continuous Improvement transformation to standardize performance and enhance operational efficiency.
Performance Optimization in Production and Laboratory Operations
- Enhanced efficiency across all value streams through one year of collaboration.
- Improved OEE, reduced changeover times, and optimized line balancing and speed.
- Implemented Lean Lab principles to consolidate resources and simplify documentation.
- Reduced and standardized regulatory documentation to increase agility and compliance.
Workforce Engagement and Capability Building
- Trained managers and site champions in daily performance reviews and problem-solving.
- Established an Operations Excellence Council for alignment, governance, and best-practice sharing.
Sustainable Continuous Improvement Culture
- Standardized Operational Excellence programs across all sites.
- Embedded accountability supported by KPI tracking and continuous improvement routines.
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.
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Ready to Build a Sustainable Continuous Improvement Culture?
- Harmonize performance and culture across sites.
- Optimize efficiency in production, labs, and office operations.
- Embed Continuous Improvement for long-term competitiveness.
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