Pfizer: Design and Implementation of Lean Operations Management

Pfizer is in the process of overseeing the build of a multiproduct API facility in Singapore.

The requirement was to develop a concept design of the Quality Control (QC) laboratory with optimum internal layout within a defined footprint i.e., what is the best layout and flow sequencing for that footprint which will give the best optimal returns from an efficiency perspective.

Eleven products had been assigned to the facility but this was subject to change so considerations for the future perspective were required.

Leading Edge Associates consultants also needed to include flexibility in the designs such as configurable and reconfigurable benches, flexible work areas, cells and work surfaces that will be the norm in the lab design of the future. The new plant will need to be configured for faster turnarounds, shorter campaigns from a small to medium volume throughput.

A set of master data had been accumulated for the new facility identifying the process steps, lots, demand, capacity, utilization, lead times, cycle times etc. from a manufacturing perspective but work needed to be done to match existing lab testing schedules to the new facility.

Outcomes:

To meet their needs of Pfizer, Leading Edge Associates built a dynamic model to determine QC testing requirements on a weekly basis for the period 2023 through to 2028

We developed a Value Stream Map of the QC testing process and established any critical constraints for consideration in layout design. Finally, we developed a number of layout concepts for the QC laboratory that would support the testing requirements and provide future opportunities for growth.