Case Studies:
Welcome to a series of operational excellence case studies, where theory meets action, and results speak louder than words. Each case study provides an in-depth look at real-world applications of operational excellence principles across diverse industries—from pharmaceuticals to machine manufacturing, healthcare to logistics. These stories capture the journey from initial challenges to transformative outcomes, demonstrating how structured approaches to process improvement can yield powerful, measurable results. In a world that increasingly values efficiency, quality, and customer satisfaction, operational excellence is a proven pathway to sustainable success. These case studies not only illustrate successful implementations but also offer valuable insights for organizations seeking similar advancements.
Each case study offers a unique perspective on overcoming specific industry pain points, from reducing lead times and cutting operational costs to improving safety standards and boosting customer satisfaction. With a focus on strategic solutions and a commitment to measurable improvement, these cases are a resource for leaders and teams eager to drive growth, profitability and resilience in their own organizations.
I invite you to explore these stories and discover how operational excellence can unlock new levels of performance and resilience across sectors. Do feel free to reach out to me if you have questions or wish to explore how your organization can benefit from these learnings.
Enhancing Operational Efficiency in Pharma ManufacturingHow Lean Manufacturing Transformed a Mid-Sized Canadian Pharma Company- A Case Study. Read More
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Lean Manufacturing in Food, Drug, Cosmetics & Chemical Industry - A Case StudyImproved productivity of pellet manufacturing by 28% per shift via LEAN Read More
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Continuous Improvement for Human Resources (HR) department via Lean and KaizenHave you ever been in a situation where there are open positions in your department that haven’t been filled out for one or two years? Read More
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Lean Innovation, Hoshin Kanrii and Six Sigma (as DFSS) for Product Design, Development and Manufacture via 3D Printing; a Case StudyLean Innovation, Hoshin Kanrii and Six Sigma (DFSS- design for six sigma) for product design, development Read More
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Kaizen in Engineering Industry: Improved Machine Utilization by 21%; a Continuous Improvement Case StudyLearn how to use Kaizen to improve Machine Utilization by 21% or more in an engineering company Read More
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Kaizen Improved Patenting and Patent Filing Process ~ 20% drop in Patenting Cost; a Continuous Improvement Case StudyLearn how to use Kaizen to manage intellectual property and reduce patent filing costs by 20% or more Read More
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Improved treatment and wound healing for burn patients at a hospital in France. Expedited patient recovery by 33%: Healthcare Continuous Improvement Case Study Healthcare is a service-based industry sector. Unlike other industries, healthcare has a lot of human angle to it Read More
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Just-in-time methodology applied to life science research and development division to improve R&D operating efficiency- A case studyJust-in-time (JIT) technique is usually applied to manufacturing and service functions of companies, but not to their R&D divisions. Read More
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Case study- Improving Scale-up And Tech-transfer Processes Via KaizenHere is a scale-up and tech-transfer process improvement success story. However, learnings of this case study could also be implements for site-transfer changes as well. Read More
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Kaizen For Innovation And Product Development: A Case StudyIn this case study, Kaizen-ing helped in improving eyedrop dropper design and its process of making. Read More
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Kaizen Saved 30% Cost on Non-Automated Packing Lines and Logistics in a Food Factory; A Case StudyLearn how to use Kaizen to save 30% or more cost on non-automated packaging lines and logistics Read More
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Kaizen to Improve Packing Department Productivity; A Case StudyLearn how Kaizen was used to improve productivity of a packing department Read More
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80% Reduction in Product Returns; A Case Study: Kaizen-based improvement in Manufacturing and Service ProcessesLearn how Kaizen was used to improve manufacturing and service processes Read More
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Lean Kaizen Reduced Cost of Logistics by 30% in a Cosmetics Company; A Case StudyLearn how to use Lean Kaizen to reduce supply chain logistics costs Read More
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Kaizen For Quality Improvement Of A Pharmaceutical Product - A Case StudyIn this case study, Kaizen was implemented to reduce variations in ophthalmic product administration Read More
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Developing ANDA Para II and III Drug Products via QbD (Quality by Design) : Innovation Management Case StudyA multi-national bio-pharma company wanted to develop Three new products via QbD methodology Read More
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How to identify 505 (b)(2) drug product development opportunities- An Innovation Management Case StudyA Global Pharmaceutical Contract Research Organization (CRO) wanted to start a new division that could develop products via the 505 (b)(2) pathway Read More
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How to reduce pricing, gain market share via Lean and Agile Kaizen? A case study in a toffee-making companyA multi-national chocolate-toffee making company wanted to reduce product price in order to overcome market competition and gain market share. Read More
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Innovation Management, Just-in-time and Kaizen Case Study in a Multi-National Pharmaceutical Company Working on ANDA Para III and IV Drug ProductsThe Innovation portfolio was strategically designed. Potential value stream maps were designed for each new product Read More
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Kaizen For Productivity Improvement Of Pellet Manufacturing: A Case StudyImplementing Kaizen improved productivity of pellet manufacturing by 28% Read More
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Business Turnaround and Innovation Management in a Global Contract Research Organization- A Case StudyA Global Contract Research Organization was sick and on the verge of being sold out. The management wanted to give a final shot for its revival prior to potential sell off. Read More
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Launching and growing a start-up R&D unit- A case study
A SE Asian bio-pharma company that sold white labeled products wanted to start indigenous research facility. Read More
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How to do speedy manufacturing site change for bio-pharma products? A Kanban and Kaizen Case StudyA multi-national bio-pharma company wanted to do a manufacturing site change for 55 products within an aggressive time frame of 5 months Read More
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How to Improve Operational Efficiency? A Lean Kaizen Case StudyA Canadian Pharmaceutical company had production issues with fifteen products and this consequently increased production back-orders. Read More
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Business Process Improvements During Mergers & Acquisitions: A Case Study in a Biotech CompanyAcquisition of a company and improving business processes post asset mergers. Read More
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Speedy Development of ANDA Para III and IV : A Kaizen Case StudyA Canadian pharmaceutical company wanted to develop products for US markets (ANDA para III and IV) in their pilot manufacturing site. What changes/ upgrades may be needed? Read More
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How to Reduce Testing Load of Analytical Labs in R&Ds? A Six Sigma Case Study in a Biotech CompanyA Canadian Biotech company had too many samples for testing in their research lab. How to cut down this analysis load? Read More
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How to Manage Inventories, Cut Wastages and Rejects in Warehouses? A Lean Six Sigma Case StudyA Canadian Drug company had huge inventory and also wastages in their warehouse. How to cut down rejects? Read More
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Business Turnaround Of A Sick Contract Research Company- A Case StudyPractising 'Daily Kaizen' has brought about swift turnaround of the sick contract research organization (CRO). Learn how Japanese Kaizen principle was used to speed-up Read More
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