Representative outcomes from major site initiatives and programs delivered through Technical Services, MSAT, and validation execution support.
Past results reflect specific client contexts and are not guarantees of future outcomes.
340+
Investigations closed
In under 6 months while maintaining inspection readiness
43
STS team built and led
Scaled from 4 to 43 engineers and scientists
3%+
Annual production cost reduction
Delivered through yield, scrap, and cycle-time improvements
11%
Yield increase
Upstream variability reduction through process and raw material controls
445k
Gallons WFI waste eliminated per year
Cleaning strategy optimization and automation improvements
20+
Audits supported
Regulatory and client audits with strong technical readiness
20+
Regulatory Documents
Authored for FDA, EMA, and Health Canada submissions
18
Clinical batches executed
Right-first-time execution with yields meeting or exceeding targets in that context
Investigation Backlog Reduction Program
340+ investigations closed in under 6 months
Implemented structured triage, clarified ownership, and established a governance cadence to drive consistent, high-quality investigations. Reduced backlog rapidly while maintaining inspection readiness.
How it was delivered
- Daily triage and clear decision rules for priority and disposition
- Templates and coaching to raise root cause quality and CAPA effectiveness
- Simple governance metrics (age, closure rate, top causes) reviewed on cadence
Upstream Variability Reduction
11% yield increase through practical control improvements
Reduced fermentation media variability and improved yield by tightening inputs, applying PAT-minded analytics, and updating controls with monitoring strategies that sustained performance.
How it was delivered
- Focused on the few input variables that materially drove yield and variability
- Aligned raw material controls and process setpoints to real manufacturing behavior
- Added monitoring that flagged shifts early without creating false alarms
Cleaning, CIP/WFI, and Utility Optimization
445,000 gallons per year WFI waste eliminated and improved CIP reliability
Improved cleaning strategy and automation execution to reduce waste, improve CIP reliability, and support consistent operation under GMP expectations.
How it was delivered
- Mapped the true constraint (cycle time, failures, waste) before changing recipes
- Optimized automation and operator workflows to reduce rework and repeats
- Documented rationale and verification evidence so the strategy held up to audit
CPV and Digital Monitoring Enablement
Standardized CPV/PAT approaches and enabled data-driven decision support
Built multivariate monitoring and CPV governance in environments using PI/Historian, SIMCA Online, and DeltaV so that quality signals drove proactive action.
How it was delivered
- Defined what decisions the monitoring must drive before building dashboards
- Separated noise from true process shifts with practical analytics
- Established governance: owners, cadence, escalation, and training for sustainment
Automated Statistical Monitoring Foundation
VBA/SQL/HTML monitoring program enabling early shift detection
Designed and implemented automated statistical process monitoring to shorten time-to-signal, reduce manual reporting, and align outputs with cGMP and data integrity expectations.
How it was delivered
- Automated data pull and cleaning to reduce manual handling and errors
- Used SPC and shift detection aligned to process capability and risk
- Delivered templates and documentation so the site could sustain without heroics