Achieving lean operations through transparency

As the demand for plasma derived therapies increases globally, Takeda's new 16,000-square-foot Quality Control Laboratory at the Los Angeles, California, Manufacturing Facility is a key element of the company's strategy to ensure a better, faster, and more economical delivery to patients worldwide. Its relocation allows for future expansion opportunities for the campus, and fully decouples the QC Lab from manufacturing operations and infrastructure.

The planning process and resulting solutions for this "next generation" QC lab reflect Takeda's commitment to not only improve the efficiency of their operation, but to give special attention to the effectiveness and well-being of a dedicated group of people who are tasked with delivering therapies that enable people with life-altering conditions to lead better lives.

Focused on operational excellence and quality, the QC Lab team, guided by their Lean Six Sigma Master Black Belt, took this opportunity to virtually disassemble their entire operation. The work flow and quality improvements that emerged from the QC lab team's Kaizen sessions became the guiding principles for the planning and design team. Based on these principles, the team developed this next-generation quality control laboratory. Capacity modeling data, manufacturing volumes, and anticipated future expansion needs were used to determine the facility's optimal layout.

Offering increased safety, quality, and efficiency, the QC Lab's design was developed with exceptional transparency and clear lines of sight. Locating management stations at the central hub of the facility increased visibility, enabling management and staff to visually verify safety, and allowing them to rapidly identify and respond to issues. The transparent design allows each team member to pursue their individual tasks while being visually connected to the overall team, promoting a shared sense of pride in their accomplishments.

The Quality Control Laboratory was the recipient of the International Society for Pharmaceutical Engineering's (ISPE's) 2018 Facility of the Year Award for Operational Excellence.