Pharmaceutical Manufacturing (GMP Plants & QC Labs)
From Firefighting to Audit-Ready: Visual Systems in Pharma GMP Operations
Challenge (Assess)
Critical GMP and QC areas were facing:
Reactive audit culture — documents and checklists were updated only before inspections.
Cluttered workstations & unclear storage — operators lost 20–30 minutes per shift searching for samples, tools, or records.
Inconsistent SOP adherence — complex procedures were hidden in files, leading to errors and rework. Solution (Solution + Identify, with Co-Design)
We worked directly with QA leads, production teams, and operators to co-design visuals that fit daily routines:
5S Workplace Organization: Teams identified what to keep, discard, and standardize → implemented labeled racks, shadow boards, and color-coded zones.
Visual SOP Boards: Reformatted complex GMP procedures into step-by-step displays at the point of use.
Compliance Boards: Co-created audit-readiness trackers with QA teams for batch release and documentation.
Safety Visuals: PPE compliance boards and emergency signage placed where teams highlighted risks.
Recognition Systems: Visual boards to showcase contributions, building pride and sustaining discipline.
Impact (Know Impact + Trigger Action)
Audit prep time reduced by ~70% (from 2–3 weeks to under 4 days).
Material search time cut by 60%, enabling faster batch preparation.
SOP compliance improved by 40–50%, reducing repeat deviations.
Employee ownership boosted: Over 80% of teams participated in co-created visual initiatives.
External confidence increased: Auditors consistently observed higher clarity and daily discipline on the shopfloor.