Streamlined Design and Implementation of Business Processes Across Multiple Sites for a Pharmaceutical Corporation

Streamlined Design and Implementation of Business Processes Across Multiple Sites for a Pharmaceutical Corporation

In a recent collaboration, Clarkston Consulting partnered with a U.S.-based pharmaceutical company to optimize business processes across multiple manufacturing sites. The project involved mapping and streamlining processes in pilot-scale and large-scale hybrid continuous manufacturing facilities, as well as supporting warehouse operations that maintain strategic reserves of critical Active Pharmaceutical Ingredients (APIs) and Finished Drug Products.

The aim was to ensure operational efficiency and supply chain resilience, preventing drug shortages and preparing for a future SAP implementation. Key approaches included workshops for alignment, comprehensive process identification considering supply chain and pharmaceutical nuances, and integration of manufacturing and warehouse processes to enable ongoing operations and coordination with contract partners.

Best practices emerging from this collaboration and related industry insights include:

1. Holistic Process Mapping and Standardization Across Facilities: Consistent and aligned processes across manufacturing and warehouse sites reduce variability, support operational efficiency, and ease technology integration.
2. Continuous Manufacturing Enablement: Mapping processes that support end-to-end continuous manufacturing workflows—from APIs to finished products—helps maintain steady production rates and quality, enhancing supply chain resilience.
3. Digital Transformation and Automation: Leveraging business process management (BPM) systems combined with automation (e.g., robotic process automation, AI/ML for document processing and predictive analytics) addresses workflow inefficiencies, regulatory compliance, and reduces manual errors.
4. Strategic Inventory and Warehouse Management: Maintaining a warehouse reserve of critical APIs and finished products helps prevent shortages during emergencies and supply disruptions. Integrating warehouse processes with manufacturing optimizes stock levels and distribution readiness.
5. Change Management and Training: Successful process digitization and standardization require comprehensive team training, technical support, and phased adoption to ensure sustainable transitions and maximize technology benefits.
6. Preparation for Enterprise Software Adoption: Process mapping supports smooth implementation of enterprise resource planning (ERP) systems like SAP by defining sustainable workflows aligned with technology capabilities, enabling scalability and future enhancements.

By following these best practices, pharmaceutical companies can improve operational efficiency and resilience, thereby helping prevent drug shortages. In this case, the client—a U.S.-based pharmaceutical company specializing in producing high-quality, low-cost pharmaceuticals using advanced manufacturing processes—can now operate in their warehouse and manufacturing areas, thanks to the completion of the business process mapping project by Clarkston. This collaboration represents a current example of how leading pharmaceutical firms harness business process mapping and digital transformation for sustained manufacturing excellence and supply chain security.

References:

[1] Clarkston Consulting. (2025). Case Study: Multi-Facility Business Process Mapping for a U.S. Pharmaceutical Company. Retrieved from www.clarkstonconsulting.com/case-studies

[2] Supply Chain Digital. (2023). The Future of Pharmaceutical Supply Chains: Continuous Manufacturing and Digital Transformation. Retrieved from www.supplychaindigital.com/pharmaceuticals/future-pharmaceutical-supply-chains-continuous-manufacturing-digital-transformation

[3] Pharmaceutical Technology. (2022). Best Practices for Implementing Continuous Manufacturing in Pharmaceuticals. Retrieved from www.pharmaceutical-technology.com/features/best-practices-for-implementing-continuous-manufacturing-in-pharmaceuticals/

[4] ISPE. (2021). Good Practices Guide for Digital Transformation in Pharmaceutical Manufacturing. Retrieved from www.ispe.org/-/media/ispe/documents/good-practices-guides/digital-transformation/ispe-good-practices-guide-digital-transformation-in-pharmaceutical-manufacturing-v2.0.pdf

1. The collaboration between Clarkston Consulting and a U.S.-based pharmaceutical company showcases the integration of technology in business processes, particularly in manufacturing and warehouse operations.
2. The project, which focused on continuous manufacturing facilities, aimed to optimize the supply chain by using holistic process mapping and standardization across various sites, reducing variability and improving operational efficiency.
3. By implementing digital transformation and automation, such as business process management systems, robotic process automation, and AI/ML, the project addressed workflow inefficiencies, regulatory compliance, and manual errors.
4. Strategic inventory and warehouse management, including the maintenance of warehouse reserves and integration with manufacturing processes, helped prevent drug shortages and ensured distribution readiness.
5. Successful process digitization and standardization were achieved through comprehensive team training, technical support, and phased adoption, which are crucial for sustained transitions and maximizing technology benefits.
6. The project prepared the pharmaceutical company for a future SAP implementation, ensuring that sustainable workflows aligned with technology capabilities were defined, enabling scalability and future enhancements in their health-and-wellness, finance, and business operations.

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