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MSD Ballydine OSD

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MSD Ballydine B-Con OSD Project

Project Value Duration Teams Collaborated with Systems Installed & Comissioned Partners Trained & Certified
€ 150M 24 Months 8 223 150

Project Overview

The MSD Ballydine B-Con OSD Project marked a strategic expansion of pharmaceutical manufacturing at MSD’s Ballydine site. Valued at €150 million, the project spanned 24 months and delivered a new three-storey extension comprising two interconnected blocks (Blocks A & B). These were fully integrated with the existing R&D and Formulation Building. Designed to support advanced Oral Solid Dosage (OSD) manufacturing, the expansion also included car parking and critical site infrastructure.

Importantly, this development bridged R&D innovation with commercial-scale production. It allowed MSD to transform scientific discoveries into manufacturing strength. A major achievement was the installation and commissioning of 223 complex, interdependent systems. Coordinated by eight specialized teams, this effort required precision and collaboration. Additionally, 150 project partners completed Lean methodology training to ensure high-performance delivery and operational readiness.

Our Project Scope (Construction & Commissioning)

Lean Touch Solutions provided comprehensive Lean Construction and Lean Commissioning services. Our goal was to embed Lean principles from design through commissioning, ensuring timely, safe, and cost-efficient delivery of the facility.

Because the project occurred within a live R&D environment and involved complex OSD processes, Lean practices were critical. We focused on optimizing system installation and commissioning, enhancing cross-team communication, and streamlining workflows. As a result, we maintained strict adherence to pharmaceutical quality and regulatory standards. Our Lean Commissioning methods notably reduced the gap between construction completion and GMP-compliant readiness.

Project Approach

Lean Construction Strategy:

From the outset, Lean Touch Solutions developed and led a unified Lean Construction and Commissioning Strategy. We collaborated closely with MSD leadership, R&D and engineering teams, contractors, equipment suppliers, and validation experts. This early alignment ensured the strategy addressed the unique challenges of live R&D integration and advanced OSD technologies.

To implement the plan, we used our standardized Lean framework. This ensured consistent application of best-in-class tools and methods throughout both construction and commissioning. Key elements included:

  • Last Planner® System – improving schedule reliability
  • Value Stream Mapping – optimizing material and process flow
  • 5S – creating efficient, organized workspaces
  • A3 Problem Solving – promoting continuous improvement
  • Optimized CQV processes – accelerating GMP readiness

Moreover, by training and certifying 150 partners in these tools, we fostered a unified, quality-focused project culture. Consequently, the MSD Ballydine B-Con OSD Project was completed on schedule, achieved full compliance, and stands ready to meet future pharmaceutical production demands.

Lean Construction process during Parliament Hotel Dublin refurbishment
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