Case Studies

Improving Capacity in a rapidly growing Cell Therpay Lab

We were engaged by a cell therapy company for a Lean Lab project addressing the challenge of rapidly increasing production volumes in analytical labs where existing operations lacked standardisation. The labs also struggled with short test turnaround times, and had no consistent system for managing the mixture of commercial, clinical, and project workloads. To overcome this, the team implemented Lean principles by collecting detailed standard work and establishing clearly defined, repeatable roles and workflows that optimised capacity and reduced scheduling effort. The development of a flow-based system of operation enabled better forecasting of resource requirements, improved scalability, and ensured consistent performance. As a result, the project delivered a 45%+ increase in productivity, achieved over 95% on-time release within 7 days, and created a robust operational framework that supports future growth while reducing costs and identifying potential equipment and capacity constraints.