BSM Lean Consultants

Streamlining QC Labs in Nutraceuticals: A Lean Transformation Success In this project with a leading U.S. nutraceutical client, our focus was to reduce QC laboratory lead time while minimizing the overall testing workload. By optimizing workflows and increasing visibility into daily operations, we achieved substantial savings and efficiency gains. 🔹 Solutions Implemented: Established a routine testing schedule for 87% of assays Launched a KPI dashboard for real-time feedback and adjustments Optimized non-routine assays to run at ideal batch sizes Standardized short-interval control practices with visual management tools 🔹 Results Achieved: 33% reduction in average lab lead time 90% decrease in overtime Over $100k in annual direct savings Enhanced visibility and control over daily lab activities This project demonstrates the impact of Lean solutions in driving cost savings and efficiency for nutraceuticals labs. #LeanLab #Nutraceuticals #QCExcellence #OperationalEfficiency #CostSavings

Is your lab drowning in complex prioritization strategies? It started with one "urgent" sample, but now, prioritization is taking over the lab's workflow, creating stress and inefficiency. The good news? This cycle can be broken. By implementing Lean principles like Levelling, Flow, and Standard Work, labs can achieve predictable throughput, minimize priority samples, and meet customer demands without the chaos. Focus on Flow and Must Start Dates to keep your lab running smoothly and reduce the stress of constant prioritization. https://lnkd.in/e6wfGVNj #LeanLab #OperationalExcellence #LabExcellence #ContinuousImprovement

Is your lab drowning in complex prioritization strategies? It started with one "urgent" sample, but now, prioritization is taking over the lab's workflow, creating stress and inefficiency. The good news? This cycle can be broken. By implementing Lean principles like Levelling, Flow, and Standard Work, labs can achieve predictable throughput, minimize priority samples, and meet customer demands without the chaos. Focus on Flow and Must Start Dates to keep your lab running smoothly and reduce the stress of constant prioritization. https://lnkd.in/e6wfGVNj #LeanLab #OperationalExcellence #LabExcellence #ContinuousImprovement

Global QC Lab Excellence Program: Transforming Performance Across FMCG Labs This multi-site program aimed to elevate laboratory performance globally for a leading FMCG client, focusing on quality, productivity, and analyst engagement. With each site’s unique lean maturity in mind, we tailored solutions to meet specific goals and improve operational transparency for global functions. 🔹 Solutions Implemented: Customized levelling, flow & standard work with new testing cells for urgent and queueable work Visual management boards for daily assignments, sample tracking, and weekly metrics 5S, Method Improvement, and Gemba practices 🔹 Results Achieved: 10-30% productivity increases across the lab network A new risk-based tool for method improvement Enhanced visibility into testing requirements Boosted analyst engagement and ownership This Lean-driven approach has laid a sustainable foundation for continuous improvement, uniting labs under a clear, efficient, and engaged operational model. #LeanLab #QCExcellence #FMCG #OperationalPerformance #LeanTransformation

📋 Dedicated Paperwork Reviewers in QC Labs: Are They the Best Solution? In many QC labs, dedicated paperwork reviewers are tasked with ensuring accuracy before test results are released. But does this desk-based approach create hidden inefficiencies? Often, it results in bottlenecks and delays, especially when review workloads fluctuate. Errors are frequently caught only days later, leading to rework and slower approvals. 🔹 Alternatives to Consider: Real Time Review™: Reviewers conduct checks throughout the day, catching errors early. Peer-to-Peer Review: Analysts review each other’s work in real time, integrating quality control directly into lab processes. By bringing review closer to testing, labs can reduce lead times, improve accuracy, and create a seamless process for faster, reliable results. https://lnkd.in/gm69T4Rg #LeanLab #QCLab #Pharma #OperationalExcellence

🚀 Case Study: Driving Efficiency and Accuracy in QC Labs for Generics In a recent Quality Control Lean Lab project for a U.S. based generics client, we focused on optimizing sample throughput from receipt through testing and review, aiming to enhance right-first-time performance and reduce time spent in review. 🔹 Solutions Deployed: Levelling, Flow & Standard Work: Improved structure in testing and review teams Visual Management: Daily work boards and weekly metrics for clear, actionable insights 🔹 Results Achieved: 23% decrease in cycle time 10% improvement in Right-First-Time test execution 33% reduction in review time Enhanced workflow clarity through daily huddles and visual cues By aligning workflows with Lean principles, we enabled sustainable performance gains and created a streamlined, scalable process for future growth. https://lnkd.in/eD3YNCiR #LeanLab #OperationalExcellence #QCLabs #Generics

📈 Surge Capacity in Labs: Is Your Lab Ready for Unexpected Workload Peaks? 📈 A good lab design handles predictable volumes, but what about unplanned spikes? Rather than carrying costly, spare resources, labs should have a surge capacity plan in place to respond to short-term workload increases. Events like equipment failures or unexpected production demands can strain resources, but planning ahead can help labs stay efficient and responsive. 🔹 Key steps: Identify causes of surges (equipment failures, production changes, etc.) Evaluate constraints (analyst hours, equipment availability, shift limits) Plan strategies (overtime, temporary resource reallocation, additional shifts, or outsourcing) A proactive surge capacity plan reduces downtime and ensures that your lab meets demands without compromising productivity. https://lnkd.in/gmtS9BQ #LeanLab #Pharma #LeanTransformation #OperationalExcellence

🚀 Scaling Up for Cell Therapy: How a Lean Lab Approach Meets Rapid Demand Without Hiring Unlike traditional pharma, cell therapy companies can't build product stockpiles before regulatory approval. This means that once approved, they must quickly ramp up production to meet patient demand, driving a sharp increase in testing volumes within QC labs. Fast, reliable release times are critical as patients await their treatments. Typically, companies might respond by rapidly hiring staff, but intensive training needs and regulatory uncertainties make this challenging. Here’s where a Lean Lab project proves invaluable. In a recent success story, our client achieved a four-fold increase in testing volume—without new hires. The Lean Lab framework implemented not only streamlined current processes but also set up a scalable structure to support future growth and hiring needs. #CellTherapy #LeanLab #OperationalExcellence #QC #Biotech

🔧 Lean Tools vs. Lean Systems: What's the Difference? 🔧 Lean tools alone don’t guarantee success. At BSM, we’ve seen labs that look "Lean" on the surface but fail to improve underlying performance. The key? Implementing Lean as a holistic system, not just isolated tools. We helped a QC lab reduce testing times by 81% using a Rhythm Wheel to match customer demand. This transformation wasn’t just about using tools—it was about creating a system that flows value at the right pace. Ready to experience Real Lean? Let’s talk. https://lnkd.in/eiHwcn3t

The standard process for batch record review involves many correction loops and excessive tracking of where the documents are and their status. In this blog we explore how Real Time Review™ can result in a a quicker, more efficient review process. #LeanQA #LeanManagement #OperationalExcellence #ContinuousImprovement