Introduction

In the competitive landscape of pharmaceutical manufacturing, maintaining consistent output levels while managing multi-departmental KPIs and resource variability poses significant challenges. Our customer experienced similar challenges. There was an inconsistency in output levels across parts of their manufacturing process. It was difficult to acutely manage multi-department KPI’s, improve functional performance when resources were managed through different vendors. The company culture was impacted by the lack of training and development provided within the function. There was also a high turnover of staff which created an inconsistency in spend/terms.

There was a pressing need by our customer for an agile and flexible solution to scale operations up or down in accordance with fluctuating demand, without compromising efficiency or quality standards.

Solution 

Recognizing the importance of optimizing manufacturing processes, Catalyx embarked on a mission to streamline operations for our customer. Catalyx conducted a comprehensive review of processes, procedures, and policies against industry best practices to identify areas for improvement. Collaborating closely with the customer, Catalyx optimized the delivery model for each area, ensuring alignment with organizational goals and industry standards. Transitioning all vendor resources to Catalyx employees enhanced control and accountability while fostering a culture of continuous improvement. Flexibility and agility were built into the model, allowing for the deployment of contingent labor to address peak demand periods. Additionally, agreed-upon KPIs were established across functions, providing a framework for performance measurement and continuous optimization.

Customer Outcomes

Exceeded KPIs Year on Year: Catalyx’s model has resulted in the consistent exceeding of key performance indicators (KPIs) year after year, indicating sustained improvement and operational excellence.

90% Reduction in Work in Progress (WIP): Since Catalyx assumed responsibility for the Quality Control (QC) function, there has been a remarkable 90% reduction in work in progress, reflecting enhanced efficiency and smoother workflow management.

Significant Expansion: The initial model, consisting of 40 resources across 2 functions, has experienced significant expansion under Catalyx’s management. It now comprises over 160 resources across 5 functions and spans 2 key sites.

Client Focus on Core Business: Catalyx’s optimized pharmaceutical processes have enabled the client to redirect their focus towards their core business activities. By entrusting Catalyx with process optimization, the client can prioritize strategic initiatives and business development efforts with confidence.