Stabilising and Transferring a Tablet Production Line
Pharmaceutical company with cross-site tablet production
Critical problems in the tablet production line led to budget escalation, production bottlenecks and frequent batch failures.
The challenge
The situation
Critical problems in the tablet production line led to a budget escalation and considerable production bottlenecks. The existing processes were inefficient and caused frequent batch failures and delays to the product launch, making a comprehensive optimisation strategy indispensable.
Our approach
What we delivered
Optimised shift planning for the production line
Upgrade of the tablet press
Strategic hire to coordinate the line
The outcome
Results & impact
Four months to launch
Product launch achieved within four months.
5% batch failure rate
Reduced rate of batch failures in the production line.
EUR 25 million budget frame
Implementation within the defined budget frame.
In summary
The tablet production line is stabilised; the product launch was achieved within four months and within the set budget frame.
Related expertise
Production Transfer & Scale-Up →
Covers exactly the EU-US site transfer of tablet production, including GMP-compliant and timely process transfer between plants.
Lean Manufacturing →
The restructured shift planning, reduced batch failures and efficiency gains in the production line are classic lean-manufacturing levers in a validated GMP environment.
CAPEX-Planung & Qualifizierung →
Modernising the tablet press to raise throughput corresponds to strategic, GMP-compliant investment planning and equipment qualification.
Lean Six Sigma →
Systematically optimising shift handovers, maintenance protocols and coordination to lower the batch-failure rate mirrors a Lean Six Sigma approach without jeopardising the GMP status.
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Sources
- Entourage project experience (anonymised)
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