Capacity Expansion and Transformation Program for Pharmaceutical Manufacturing, Leading to a 25% IncreaseCAPACITY INCREASE

SITUATION

Pharmaceutical Company Facing Capacity Constraints

 

Current Situation:

  • High Demand: Rising need for plasma-derived medication for rare health conditions exceeds current production capacity.
  • Limited Output: Existing facilities unable to meet the growing market demand.
  • Critical Challenge: Need for significant operational overhaul to scale up production.
  • Transformation Goals:
  • Enhance Production Capacity
  • Optimize Operations:
  • Meet Demand

APPROACH

  • Conducted a comprehensive diagnostic of the entire value chain.Uncovered key levers for capacity improvement, emphasizing quality and employee well-being.Designed a detailed transformation roadmap featuring 8 major projects and approximately 190 initiatives.Structured and trained transformation teams in project methodology using specialized tools.Directed the transformation program through both design and implementation phases.

 

  • Revealed a potential 25% increase in capacity.

IMPACT

  • Established comprehensive governance across sites with the leadership team and operational staff.
  • Launched the first wave of projects, encompassing approximately 40 major initiatives, which contributed to 50% of the overall capacity increase.
  • Initiated projects focusing on:
  • Activity Organization
  • Process Reliability
  • Scheduling
  • Quality Excellence
  • Training and Certification
  • Performance Management

KEY FACTS

 

25% increase in capacity

190 initiatives defined in details

New governance in place

+30 people trained to new project management methodologies

 

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