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 set-up 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.
