How we boosted a COVID-19 vaccine production by digitally enhancing manufacturing operations

The Challenge

In response to an unprecedented global pandemic, our client – one of the pharma industry leaders – set out to develop, test, mass produce and organize the global distribution of a COVID-19 vaccine.
The company was already implementing a strategic project to digitize its manufacturing processes. In cooperation with C&F, our customer had already achieved measurable successes in implementing the Digital Operations Center (DOC). However, as world-wide attention shifted to finding a vaccine to help end the pandemic, the DOC program did a very effective pivot mid-way through to put its undivided attention on supporting the efforts to expedite the manufacturing of this much needed COVID-19 vaccine.

Problems to solve

  • Pivot the project mid-way through to focus on the COVID-19 vaccine production without slowing down any existing drug manufacturing operations
  • Provide full visibility of the product (vaccine) through production & supply chain
  • Improve production yield and cycle time
  • Reduce errors and risks in production and quality control

The solution

Implementation of the DOC – a suite of digital solutions to support manufacturing operations, enabling timely manufacturing and supply decisions across the organization:

  • Visual Management Actions & Metrics
  • Continuous Improvement (CI) Loop
  • Standard Work Planning and Execution
  • Incident Board
  • Continuous Improvement (CI) Analytics
  • Leadership Ecosystem for Above Site Operations

Results

Bottleneck cycle time reduced

Better Manufacturing Attainment

Intersite Service Level Increased

Days Reduced Cycle Time

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Pharmaceutical companies that have taken up the challenge of producing a coronavirus vaccine faced two major and equally important tasks: vaccine development and vaccine manufacturing. Despite facing unprecedented challenges, in less than a year they delivered with the help of manufacturing digitization.
Michael Mercurio | Vice President, Client Services

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