Client Success Story

Background

A global biotech manufacturer launched an ambitious, industry-first digital manufacturing initiative to advance manufacturing excellence across its global network. The vision was to create a single point of entry digital solution that could visualize, optimize, and standardize manufacturing processes. The system's goal was to integrate information vertically, from the shop floor to above site leadership while creating visibility across site production processes. The platform was designed to provide real-time operational visibility, enable data-driven decision-making, and establish a common foundation for continuous improvement.

The solution was intended to serve a broad and diverse user base; including shop floor operators, manufacturing supervisors, site leadership, and global operations teams. By delivering a one-stop shop for manufacturing insights and execution, the organization aimed to reduce operational variability, improve performance transparency, and scale best practices across its global footprint. Over time, the platform scaled to more than 20 manufacturing sites and 20,000 users worldwide, becoming a core enabler of manufacturing excellence.

Company size

Revenue

Scope

30,000+ employees

$10B+

Manufacturing excellence and standardization

The Challenge

Achieving this vision required overcoming significant technical, operational, and organizational challenges. Manufacturing processes and performance measurement varied widely across sites, with each location operating under its own organizational structures, local practices, and definitions of success. While global standards existed, they were inconsistently applied, making it difficult to compare performance, identify improvement opportunities, or scale best practices across sites and across-site processes.

Data availability and accessibility posed another major challenge. Critical manufacturing data resides in a complex ecosystem of legacy systems, paper-based records, and manual processes. Real-time process data was siloed and primarily captured in the operational technology (OT) layer. Integrating these disparate data sources into a single digital platform required careful consideration of system compatibility, data quality, and regulatory compliance.

In addition, the solution needed to balance global consistency with local flexibility. Each manufacturing site required the ability to measure and manage its processes in ways that reflected local realities, while still aligning to enterprise-wide standards for quality, performance, and compliance. Driving adoption at scale also required engaging a wide range of users with varying levels of digital maturity, all while maintaining a strong focus on manufacturing excellence and operational discipline.

Manufacturing sites

Inconsistent standards

Operations

20+

Paper based processes and inconsistent standards across site network

• Drug Substance

• Drug Product

• API

• QA / QC

Our approach

We partnered closely with manufacturing, quality, IT, and operations leadership to design and deliver a scalable digital manufacturing platform grounded in manufacturing excellence principles. The initiative began with a focused pilot in a drug product manufacturing suite, engaging approximately 100 users. This pilot allowed us to validate core capabilities, refine user experiences, and demonstrate tangible value in a controlled, high-impact environment.

Using insights from the pilot, we designed standardized, but configurable manufacturing process models, KPIs, and visual management frameworks that aligned with global standards. We integrated data from legacy manufacturing systems and digitized paper-based and manual processes to create a single source of truth for operational performance. Real-time dashboards, role-based views, and digital workflows enabled users at every level to monitor execution, identify deviations, and drive continuous improvement.

Following the successful pilot, we executed a phased, site-by-site rollout supported by strong business support, change management, training, and site enablement. This approach ensured consistent adoption while respecting differences in site maturity and organizational structure. As additional sites onboarded, we continued to evolve the platform, incorporating feedback and expanding capabilities to support cross-site visibility and benchmarking. The result was a globally scaled digital manufacturing solution that embedded manufacturing excellence into daily operations, connected over 20 sites and 20,000 users, and provided a sustainable foundation for operational performance and continuous improvement.

Scaled users

Manufacturing Hub

20,000 users scaled globally

One stop shop for manufacturing operations and performance

Key Client Successes

By delivering a globally standardized yet configurable digital manufacturing platform, the initiative connected over 20 sites and 20,000 users, established a single source of truth for operational performance, and embedded manufacturing excellence into daily operations across the enterprise.

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