Sector: Pharmaceutical
Core Processes: Vaccine development, manufacture, filling and packing
Background
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
How?
- First to Market
- Utilisation of Resources
- Optimal use of Lab facilities
- Optimal passes
- Simultaneous work
- Flexible shift pattern
- Structured seed protocol
- Utilisation of Resources
- 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
Benefits
- 30% Increase in primary doses
- 30% reduction in leadtime
- Multiple strain capability