Lean Operations Diagnostic in Pharma

THE CHALLENGE

Efficiency in pharmaceutical manufacturing

Efficiency in pharmaceutical manufacturing is critical to ensuring a steady supply of life-saving treatments. Yet, a leading European pharmaceutical company faced severe production inefficiencies in sterile syringe filling. This caused frequent stoppages, extended lead times, and threatened the supply of critical therapeutics to patients.

OUR SOLUTION

Lean Operations Diagnostic Benchmark to address inefficiencies

To tackle these challenges, we used a Lean Operations Diagnostic to provide a clear, data-driven assessment of site performance. We benchmarked operations against industry standards, uncovering bottlenecks and defining four key areas for immediate action:

Rapid maintenance interventions to prevent equipment stoppages
Optimize performance management systems to improve efficiency
Address process deviations to enhance quality and consistency
Eliminate service blockages to streamline workflows

This diagnostic-first approach allowed for a targeted, strategic improvement plan—not just a consulting report, but a clear, actionable roadmap for sustainable transformation.

THE RESULTS

One step closer to pharma manufacturing excellence

Throughput increased by 32% within 12 months—without major capital investment
Lead times were cut in half, significantly improving responsiveness
Supply shortages dropped from 30 to zero, ensuring reliable patient access

With the Lean Map Diagnostic at the core of this transformation, the company not only met patient demand but also moved one step closer to pharma manufacturing excellence.

Want to ensure your manufacturing site is operating at its full potential? Let’s connect and explore how our Lean Operations Diagnostic can drive measurable results for your operations.

The team