GMP MANUFACTURING
CYCLE TIME REDUCTION

PROJECT OVERVIEW

CAI partnered with a leading U.S. pharmaceutical manufacturer to address inconsistent and prolonged GMP manufacturing cycle times. Using its Operational Excellence framework and DMAIC methodology, CAI identified bottlenecks in inter-batch operations and implemented data-driven improvements. Key actions included optimizing line clearances, redesigning workflows, creating visual management tools, and improving training. These efforts reduced TBB duration by 36% and variability by 49%, resulting in record production performance. The project showcased the value of structured problem-solving and reinforced CAI’s role as a trusted partner in driving sustainable productivity in complex pharmaceutical manufacturing environments.