Category Winner for Operational Excellence
Merck & Co., Inc. with SKAN as a key participant
Vaccine and Biologics Sterile Facility (VBSF)
"Merck needed to make a strategic investment in its manufacturing network to support its long range biologics and vaccine pipeline, resulting in the VBSF project in Carlow, Ireland. This was Merck's first green-field sterile processing facility built outside the US and from the beginning, the project team was committed to employing a Lean Six Sigma philosophy as the foundation for every part of the project.
Lean Six Sigma was used by the team to manage the dynamics of the decision process during the early project scoping, design, and integration activities and the formation of a "One Team" culture. In addition, many focused Lean projects were done independently and seamlessly integrated back into the larger program, including design of the syringe filler, eBeam reliability, and media/buffer suite design. Lean Six Sigma was also employed during project execution, where the methodology drove efficiency of decision making and rapid implementation of remediation measures.
Lean Six Sigma was successfully applied in every facet of this project, prompting judges to select the VBSF project as the winner in the Operational Excellence category."