Case studyPharma

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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