Plant Performance improvement in the pharmaceutical sector

The mission

In the highly regulated healthcare sector, a pharmaceutical company sought to optimize its plant performance and minimize non-quality costs. This challenge required a strategic approach to ensure both regulatory compliance on the production chain and operational excellence.

The approach

We implemented a comprehensive program to identify and implement cost-optimization opportunities across the production lifecycle:

• Quick wins & long-term gains: we identified a strategic mix of „quick-win“ solutions for immediate impact and long-term initiatives (related to orgazination, automation, production planning, bath records…) for sustained improvement.
• Optimizing Key Processes: Our focus targeted critical areas for performance improvement in the healthcare sector, including change of batch (main source of time-loss) and quality control procedures.
• Through on-site observations and analysis, we identified optimization levers to streamline operations.
• Transparent Communication: we maintained a continuous feedback loop with line managers, ensuring buy-in and successful implementation.

The impacts

• -15% of identified savings on accessible scope (initial target 11%) from which 35% have directly been integrated in year+1 budget
• 30+ cost-innovative opportunities identified among 7 services (production, packaging, logistics, quality, planification, maintenance)
• Highlight of annual savings throughout the next 4 years