Case Study – Global Packaging Design Management

Transforming global product packaging and artwork design and development capabilities.

Click on the tabs below to read about these success stories.

Global Packaging Design Capability Strategy Development
Top 5 Global Pharma Company. 
Situation
The company wanted to reduce it’s recall rate due to packaging design, whilst at the same time be able to understand and reduce the complexity of it’s pack range and associated components. The company’s packaging and artwork design capability had evolved over many years into a complex, disparate global collection of operations which made the task almost impossible to achieve.  
How We Helped
Members of our team ran a strategy development project which delivered the following: •   Full understanding of the complex current situation •   Future state operating model, including a global service center network •   IT architecture to support the new operations •   Change programme design to deliver the new capabilities •   Buy-in from more than 300 stakeholders across the world to the recommendations 
The Results
The company went on to implement this strategy in it’s entirety.

20,000 Changes per Year Global Packaging Design Capability Implementation
Top 5 Global Pharma Company.
Situation
Having already helped this company to develop a strategy (see another one of our success stories), this company needed to implement a new global operating model across >100 markets and >25,000 sku’s.
How We Helped
Members of our team ran this significant global change programme which involved the following elements: •   New global process design for 2,500 users in >100 locations. •   New organisation design including a small number of global service centers. •   New enterprise PLM and artwork desktop IT capability design. •   New governance model. •   Phased implementation of the change, including closure of many existing operations. •   Pack range rationalisation programme.
The Results
The new capability has helped the company reduce it’s recall rate, improve speed to market and reduce the cost of its packaging. The change programme and the resulting capabilities have won a number of internal and external awards for innovation and excellence.

Global Packaging Design Capability Upgrade
Top 5 Global Pharma Company.
Situation
The company had been operating a significant global pack change capability for a number of years. The Product Lifecycle Management (PLM) Information Technology (IT) platform which underpinned it had reached the end of it’s service life and needed upgrading. The company also had a significant list of improvements that it wanted to make to the buiness processes and IT, but had been prevented from doing so by constraints in the existing IT platform.
How We Helped
Members of our team ran this significant global project which involved the following elements: •   Defining improved business processes. •   Introducing a new suite of pack change planning and resource management tools. •   Upgrading the entire IT platform. •   New governance model. •   Migrating all existing data to the new platform. •   Training thousands of users in the new processes and IT tools. •   Cutting over thousands of users in hundreds of locations to the new processes and IT platform. •   Re-establising better than pre-cutover performance of the global operation.
The Results
The new business processes and IT platform were introduced with no adverse impact on internal or external pack change requirements. The improved capabilities have significantly improved the company’s ability to manage individual and groups of pack changes to plan. It is also enabling further improvements to be made in the way resources are managed and the efficiencies that are being achieved. The project and the resulting capabilities have won a number of internal and external awards for excellence and quality.

 

Late Pack Customisation for small volume blister packs
Top 5 Global Pharma Company.
Situation
The company had a significant portfolio of blister packs with unpredictable demand and extremely small order volumes. Minimum order quantities resulted in many months forward cover and high obsolescence risk.
How we helped
Members of our team delivered an innovative packaging design that allowed small volume product to be late customized with local language labelling and product information.
  1. We established the project team comprising commercial, regulatory, manufacturing, supply chain, quality, packaging design, equipment design and equipment suppliers.
  2. We established the necessary cross-functional governance.
  3. We co-ordinated implementation.
The results
Increased market sales through better availability of product. Reduced working capital and obsolescence.
This project won a Starpack Gold Star Award for Late Pack Customisation.

Solid Dose Packaging Strategy
Top 5 Global Pharma Company.
Situation
The company had a global network of solid dose formulation and packaging sites. The majority of these sites supplied a small number of brands on a global basis. This network design was creating a number of inefficiencies:
  • Packaging capacity was not optimised.
  • Component formats and sizes were locally defined.
  • Regional legislation (e.g. Braille) impacted the global supply network.
  • Best practice was not being shared.
  • Equipment design and sourcing was undertaken locally.
  • Product was distributed globally to local in-country warehouses, resulting in high working capital and shipping costs.
How We Helped
Members of our team led the development of a global solid dose supply strategy leading to a move to regional packaging and distribution hubs. In this we:
  • Mapped the existing supply chain and portfolio to determine product flows, volumes and costs.
  • Defined and evaluated to-be network options.
  • Led the assessment of suitable hub locations.
  • Designed and sized the packaging and warehouse operations in each hub.
  • Reviewed and rationalised the product and component portfolios.
  • Defined the business case and facilitated approval.
  • Transitioned the programme into implementation.
The results
Gained approval for a GBP50m rationalisation of packaging locations and supply chain, refocusing to a regional packaging model, including:
  • Development of new packaging processes, organisational model and capabilities to achieve industry best-practice KPIs whilst ensuring compliance to legislative trends.
  • Standardisation of packaging equipment (50% reduction), components (75% reduction) and SKUs (40% reduction).
  • Simplification of downstream supply chains through a multi-market warehouse model.