GMP Manufacturing Cycle Time Reduction

Variability in Time Between Batches (TBB) is a silent productivity killer in GMP manufacturing. When a major pharmaceutical facility faced inconsistent execution and limited visibility into process constraints, the solution required more than just faster work; it demanded a structural shift. By applying a data-driven Operational Excellence framework, the facility identified specific bottlenecks, such as redundant robot line clearances and outdated standard operating procedures.

The intervention led to a 36% reduction in TBB duration and, perhaps more importantly, a 49% decrease in variability. This approach proves that utilizing the DMAIC problem-solving framework to analyze inter-batch manual operations can yield record performance results. Download the full case study to explore the specific methodologies used to achieve these operational gains.