Environmental Monitoring
Objectives
Our client, a leading pharmaceutical company, engaged us to help reduce their substantial overtime spending.
Solutions Deployed
- Redesign of process flows to remove redundancies
- EM and Water sampling plans designed to limit travel time and level number of samples collected daily
- Queue-based leveling employed to reduce testing volatility
- Cross-training plan implemented to reduce analyst test dedication
- Created balanced, productive daily roles for analysts
- Implemented a consumable inventory management system to control ordering and reduce the frequency of media receipt
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Results
- Daily EM and Water sample collection volatility reduced by 83%
- EM and Water sampling time reduced by 30-57%, respectively
- Membrane filtration and spread pour plate reads reduced by 43%
- Endotoxin testing runs reduced by 60%
- Material ordering/receipt reduced by 45%
- Growth promotion testing reduced by 53%
- Cross training increase of 30%
- Productivity increase of 50%
- Released 1 FTE from sampling/testing to focus on studies/projects
- Overtime reduced by 90%
- Direct savings of >$200,000 per year
