From Firefighting to Reliable Supply
The Challenge
A single site within 30+ site network of a global pharmaceutical company performed fill-finish of a lifesaving, high-demand drug. With patient demand climbing and the site consistently falling short of its supply plan, the goal of the project was to meet patient commitments, while ensuring regulatory compliance, and enhance reputational standing at the corporate level.
Our Analysis
3 years of manufacturing plan versus shipments, combined with value stream mapping across each vial filling line revealed the following underlying causes:
- A highly motivated workforce that was constrained by process and planning gaps
- Manufacturing plans built on individual local/tribal knowledge rather than on data-driven capacity models
- Chronic shortfalls against annual manufacturing plan
- Lack of hard evidence to win corporate investment for needed structural changes
What We Did
Implemented a series of situation specific, customized solutions that combined data analytics, process discipline, and above all, leadership engagement:
- Capacity Modeling: Built a data-based model of actual line throughput and bottlenecks. Then applied Six Sigma DMAIC methodology to identify the true root causes of those bottlenecks, created a detailed plan address them and finally, implemented that plan.
- Standardized Planning: Transitioned from “tribal knowledge” to repeatable, data-driven planning processes
- Strategic Redundancy: Introduced standardized approaches to reduce disruption risk and build resilience
- Corporate Advocacy: Equipped site leadership with compelling, data-backed evidence to secure corporate alignment and investment
The Measurable Results
- Significant throughput improvement across vial filling lines in the first 12 months
- Increase in planning accuracy, eliminating chronic overpromising
- Reduction in supply risk exposure through process standardization and redundancy
- Corporate funding approved for capacity expansion, driven by leadership’s confidence in the site’s data-driven strategy
- Most importantly: patients received their medicine reliably and on time