Challenge
A private equity-owned pharmaceutical contract manufacturer was growing rapidly but struggled to meet customer orders and quoted lead times due to scheduling instability and inefficient production.
The company needed help implementing Lean production methods to optimize scheduling and improve line performance to unlock growth potential.
Approach
- Analyzed operational and financial data to assess equipment performance and validated analysis with on-the-floor observations and company stakeholders
- Added standard lean daily management to highlight wins & drive corrective actions across the plant floor
- Implemented frozen zones within production schedule to reduce interruptions and meet lead times
- Re-designed SIOP process, supply agreements, vendor management, and inventory policies to align operating model with go-to-market strategy
Results
Unlocked line capacity to facilitate anticipated +20% Year over Year growth within same cost structure with minimal CAPEX deferring expansion
Increased unit volume growth by 50% within 6 months
Reduced external lab spend by 15% while decreasing quality issues and lab errors through improved process controls
Implemented comprehensive BI tool to provide view of financial, operational, and quality KPIs