$6B
Annual blockbuster drug revenue
Lean Lab Transformation Boosts R&D Capacity by 29% in Pharma
A leading pharmaceutical company partnered with EFESO to increase workload capacity at its R&D facility while maintaining schedule adherence for ongoing projects. Through Lean Lab methodologies and optimized planning, the client achieved significant gains in lab utilization and operational efficiency without additional resources.
Industry: Life Sciences
Our Client
The client is a leading pharmaceutical company whose R&D facility is responsible for developing the next generation of biologically derived drugs, including a $6 billion-per-year blockbuster. The site’s advanced bioreactor lab required optimization to unlock additional capacity and support accelerated innovation.
The Challenge
The client needed to increase project workload capacity at their Research & Development (R&D) facility while maintaining schedule adherence for current project workloads.
The project aimed to optimize and increase the utilization of advanced bioreactor laboratories at a site responsible for developing the next generation analogues of a portfolio of biologically derived (large molecule) drugs.
Real Results Achieved Together
Through the implementation of lean laboratory methodologies and optimized planning processes, the pharmaceutical R&D facility achieved significant improvements in capacity utilization and operational efficiency.
+29%
Increase in advanced bioreactor lab utilization
Transformation Impact
- A robust capacity planning process maximized equipment utilization, freeing scientists to focus on innovation while minimizing time spent on non-value-added activities.
- A standard rhythm wheel leveling strategy, visual management systems, and structured workflows further strengthened consistency and performance.
- Significant reduction in downtime due to enhanced planning and re-engineered changeover processes
- Marked increase in overall project workload capacity without additional equipment or scientist resourcing
Our Approach
EFESO supported the transformation by:
- Optimizing the utilization of the advanced bioreactor lab while improving the schedule adherence of current project workloads.
- Strengthening the robustness of the capacity planning process for all projects to maximize equipment utilization and allow scientists to focus on scientific innovation.
- Implementing a rhythm wheel leveling strategy for the preculture processes.
- Establishing standard work practices for sampling and the analysis of results.
- Introducing an electronic visual management system to plan, monitor project progress, and report instructive KPIs.
