To excel at every stage of the pharmaceutical value chain, it is crucial to align operational efficiency with value delivery. This ensures not just cost reduction and streamlined processes but also breakthrough results and sustainable growth. 

Long manufacturing lead times, Equipment downtimes, complex and time consuming R&D process, Skilled manpower availability, high attrition and consistent product quality are some of the key challenges in pharmaceutical industry, 

Our Lean experts with deep understanding of implementing operational excellence and continuous improvement tools in the pharmaceutical industry, help fuel innovation, reduce costs, reduce operational lead time, enhance equipment efficiency, reduce material losses leading to substantial improvement in production output. 

With experience across different sectors including  Tablets & Injectables, API (Active pharma ingredients), Medical Equipments manufacturers and Pharma distributors, we bring in valuable insights and solutions customised to every organisation.


Operational Excellence in Pharmaceutical Value Chain

Manufacturing Excellence

  • Reduce Manufacturing lead time including batch wait times, cycle times with flow manufacturing,  plant layout improvements and Real-Time Quality Control (RTQC)
  • Enhance Packaging line productivity with Lean Ergonomic Workstation Design, Cellular Layout, line balancing and standard work

Overall Equipment Efficiency (OEE) Improvement

  • Reduce Equipment downtimes  with Total productive maintenance 
  • Reduce batch & product changeover times with SMED

Quality & Yield Improvement

  • Reduce Yield losses, defects & variation  with Six sigma and TQM tools
  • Use of Standard Work to ensure consistent quality

New Product Development and R&D Excellence

  • Agile project management, Last planner system and set based engineering to reduce new product development lead time
  • Streamline R&D activities, improve collaboration, and reduce bottlenecks

Supply Chain Excellence

  • Improve On time in full error free (OTIFEF) delivery to customers and reduce delivery turnaround time
  • Optimise inventory levels & eliminate stock outs 
  • Minimise inventory losses due to expiries and dead stock

Sales Operations Efficiency & Productivity

  • Accelerate performance of sales teams by eliminating MUDA  
  • Transform sales team efforts to implement  improvement breakthrough strategies with focus on high impact markets and core products
  • CI based sales model leading to higher productivity and improved sales per person

Our Pharmaceutical Consulting Impact

0 % -30

Manufacturing lead time reduction

0 % -30

Rreduction in unplanned downtimes

0 % -50

Reduction in defect rates

0 % -25

Reduction new product development time

+ 0 % +35

OTIF performance improvement

Our Pharmaceutical Sector Expertise

Pharma Distributors

As a critical component of the healthcare supply chain, ensuring faster delivery turnaround times, optimum inventory levels. streamlining processes and reducing operational costs is essential to meet market needs efficiently and effectively. We can help you drive the right strategy and tools at every stage of the value chain.

Pharma API (Active Pharma Ingredients)

We can help you optimize API manufacturing and provide a structured framework to address the complexities of API manufacturing. By implementing Continuous improvement tools, companies can overcome long lead times, high rejection rates, and frequent equipment breakdowns and changeover times

Medical Equipments & Devices

The manufacturing of medical equipment and devices requires high precision, stringent quality control, innovation and customisation to improve clinical outcomes and enhance patient care. We can help you improve manpower productivity, reduce manufacturing lead time, minimise defects and optimise inventory levels.

Tablets and Injectables

Our Lean Kaizen experts can provide you transformative solutions to tackle challenges in tablet and injectable manufacturing with flow manufacturing to reduce lead time, improve yield, reduce equipment downtimes, defects and product variability, thus reducing production costs.


What to Expect?

Increase in Production output

Reduction of manufacturing lead time

Increase in Manpower Productivity

Improvement of On time delivery

Reduction of material losses

Increase in Sales per person

Improvement in New Product Development turn around time


Our Pharmaceutical Clients

Abbott pharmaceuticals, India

Dr Reddy’s Laboratories, India

Medsource Ozone biomedicals, India

RA Chem, Pharma, India

Bushu Pharma, Japan

Adwia, Egypt

PHI, Morocco

Celon Labs, Hyd, India


By leveraging Lean Kaizen principles, the pharmaceutical companies can achieve operational excellence, deliver high-quality products faster, and remain competitive in a rapidly evolving market.

Connect with our Experts!

With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!

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