Real Lean Transformation

Biopharmaceutical Research & Development

Client Environment

Biopharmaceutical (Large Molecule) API Research and Development Organization



Lean R&D Project in USA.



Our client, a leading pharmaceutical company, engaged us to increase project workload capacity at their Research & Development (R&D) facility whilst improving the schedule adherence of current project workloads. The project was charged with optimizing and increasing the utilization of advanced bioreactor laboratories, at a site that was responsible for the development of the next generation analogues of a portfolio of biological derived (large molecule) drugs, including one $6 billion/year blockbuster.


Solutions Deployed

  • Robust capacity planning process for all projects that maximized equipment utilization and afforded scientists time to focus on scientific innovation whilst minimizing time expended on non-value added tasks.    

  • Rhythm wheel levelling strategy for preculture process and established standard work practices for the sampling and analysis of study results.

  • Electronic visual management system to track and monitor progress of projects and report instructive Key Performance Indicators (KPI’s).



  • Increased average bioreactor utilization by 29%.

  • New planning process and re-engineered changeover process for bioreactors resulted in significant reduction of bioreactor downtime.

  • Marked increase in overall project workload capacity without the need for additional equipment or scientist resourcing.