Lean FLU Results In 30% More Doses


Sector: Pharmaceutical
Core Processes: Vaccine development, manufacture, filling and packing


Whilst the client are in a very strong position in the marketplace there is a real desire to support the future of the site and the Manufacturing Management team have taken the decision to implement Lean Manufacturing Principles with the objective of developing a World Class manufacturing facility.

The seed labs are the first step in the process in vaccine manufacturing process. After an £8million investment in new world beating labs the seed team wanted to develop a world beating process to maximise the opportunity.

Project Objectives

  • First to Market – reduce by 30%
  • Produce Seeds with capability to Exceed saleable doses – increase by 30%
  • Reduce Cost of Goods
  • Turn our World Class facility into Centre of Excellence for Seed Manufacture
  • Best practice Protocol for Seed introduction
    • Lean
    • Compliance


  • First to Market
    • Utilisation of Resources
      • Optimal use of Lab facilities
      • Optimal passes
      • Simultaneous work
      • Flexible shift pattern
      • Structured seed protocol
  • Exceed Saleable Doses
    • Maximise each Strain’s Yield potential with Structured seed protocol
  • Reduce Cost of Goods
    • Intra-Departmental balanced labour requirements
    • Multi-skilled associates
    • Cross-Site / Inter-Departmental labour pool
  • Turn World Class Facility into Centre of Excellence
    • Use Lean Best Practise
    • Define feedback from the Process
    • Refine the appropriate protocol
    • Develop model for measuring seed performance in the overall process



  • 30% Increase in primary doses
  • 30% reduction in leadtime
  • Multiple strain capability