Halving the cycle time: how we radically increase throughput in GMP production
Did you know that even small adjustments in process design can have a significant impact on efficiency and costs? In GMP production in particular, upstream and downstream processes are often complex and strictly regulated. But this is precisely where our expertise comes in: With targeted optimizations, we show how cycle times can be drastically shortened and production capacities enormously increased.
As part of a current project in antibody production, the challenge was to reduce the cycle time to a minimum and thus maximize the number of batches per year. In each case, taking quality and GMP compliance into account.
Our approach
Process analysis & value stream design: We scrutinize the entire production process - from upstream to downstream to logistics - and identify potential bottlenecks.
Plant layout & infrastructure optimizations: An optimized sequence of process steps, adapted cleaning sequences and verification of infrastructure capacity with cycle time reduction ensure a smooth process. Future scenarios can thus be tested.
Operator planning: The complex work processes - from production steps to analytics, logistics and cleaning - require precise planning of shifts. This is where we provide support in optimally utilizing the employee pool.
Process standardization & training: Together with your team, we define new or optimized processes and provide in-depth training so that everyone involved can work safely and efficiently.
The result
More throughput: over 30% increase with consistently high quality and GMP compliance. Reducing the cycle time to less than 10 days revealed bottlenecks in downstream equipment, operator resources and waste disposal. In order to meet these challenges at an early stage, the procurement of additional equipment and other measures are planned to ensure smooth operations.
Cost reduction: The production costs per batch have been significantly reduced.
On-time delivery: Resource bottlenecks were avoided and schedules were made more transparent in order to maintain the cycle time of less than 10 days over a longer period of time in future.
Conclusion
Ob Dimensionierung von Anlagen, Ressourcenplanung oder Engpassanalyse – eine fundierte Prozessoptimierung zahlt sich aus: höherer Durchsatz, besseres Kosten-Nutzen-Verhältnis und gesteigerte Wettbewerbsfähigkeit.
Curious?
If you are facing similar challenges in your GMP production, let's talk. We at pixon engineering AG look forward to supporting you in increasing the efficiency of your processes!
