Challenge
A commercial biologics line experienced high cycle-time variability and suboptimal batch sequencing, which led to yield loss, downstream bottlenecks and unpredictable cost-to-produce calculations that hampered pricing and margin planning.
Approach
We mapped end-to-end production flows and identified key drivers of cycle-time variability. Working with site operations, scheduling and tech transfer teams we redesigned batch sequencing rules, implemented standardized scheduling templates, and introduced targeted process changes to reduce setup and changeover times. We embedded key OEE and cycle-time metrics into the client's ERP/BI reporting so site performance could be measured and trended in near-real time.
Impact
The pilot produced measurable throughput improvements and lowered cycle-time variability for the target line, clarifying the major drivers of COGS and creating a repeatable playbook for scaling the improvements across additional lines. The client gained stronger margin visibility and a defined roadmap for broader roll-out.
