Stabilizing 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 optimization strategy indispensable.
Our approach
What we delivered
Optimised shift planning for the production line, to resolve the bottlenecks that were delaying the launch.
Upgrade of the tablet press in response to the frequent batch failures originating from the equipment itself.
Strategic hire to coordinate the line, so that the optimisation has someone accountable for it beyond the project period.
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 stabilized; 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 Planning & Qualification →
Modernizing the tablet press to raise throughput corresponds to strategic, GMP-compliant investment planning and equipment qualification.
Lean Six Sigma →
Systematically optimizing 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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