...

MSD Ballydine API

takt

B-CON API Project MSD (Ballydine), Ireland

Project Value Duration Teams Collaborated with Systems Installed & Comissioned Partners Trained & Certified
€ 150M 36 Months 10 176 180

Project Overview

The B-CON Active Pharmaceutical Ingredient (API) Project for Merck Sharp & Dohme (MSD) in Ballydine marks a pivotal investment in securing Ireland’s pharmaceutical production capacity. Valued at €150 million, this cutting-edge facility was delivered over a 36-month timeline—from design through to operational readiness.

The project entailed the creation of a dedicated, greenfield API manufacturing plant, where the core components of life-saving medicines are produced. Jacobs Engineering’s Life Science division served as the design and integration lead, overseeing the facility’s development from detailed engineering to system implementation.

This facility was built to meet stringent global GMP (Good Manufacturing Practices) standards for API production. It included highly technical processes, specialized equipment, and precisely controlled environments. Over the course of construction, 10 specialized teams collaborated to install and commission 176 advanced systems. In parallel, 180 project partners were trained and certified in Lean methodologies, reinforcing a culture of efficiency and quality from day one.

Our Project Scope (Construction & Commissioning)

Lean Touch Solutions was engaged to implement a comprehensive Lean Construction strategy specifically tailored for this complex pharmaceutical environment. Our core mission was to align with MSD’s goals: deliver the project on schedule, adhere to regulatory standards, and uphold exceptional safety and quality levels.

Constructing a new API facility brings inherent complexity—tight regulatory oversight, technically intricate system installations, and high-risk integration challenges. In response, we applied Lean principles not as an add-on, but as a core strategy embedded across the project lifecycle. We focused on:

  • Improving workflow reliability
  • Reducing waste across materials, time, and manpower
  • Enabling seamless coordination across all technical and trade disciplines
  • Proactively managing risks that could affect schedule or compliance

This allowed the team to maintain predictability and control throughout the delivery process.

Project Approach

Lean Construction Strategy:

Our approach was grounded in the collaborative development of a bespoke Lean Construction strategy designed to address the unique challenges of API facility construction. From the outset, we partnered closely with:

  • MSD’s project leadership
  • Jacobs Engineering (design & integration lead)
  • Main contractors and trade partners
  • Specialist vendors and automation experts

Through early and continuous engagement, we embedded Lean thinking into project planning, influenced constructability during design phases, and secured alignment on efficiency goals. This shared commitment was essential to maintaining momentum and fostering a high-performance delivery culture.

Our work followed Lean Touch Solutions standardized Lean Construction Implementation Framework, ensuring consistent use of proven tools and practices such as:

  • Last Planner® System – for accurate and dependable scheduling
  • Value Stream Mapping – to streamline end-to-end workflows
  • Pull Planning – to align sequencing with just-in-time resource delivery
  • A3 Problem Solving – to address issues early and systematically

Moreover, our holistic Lean approach extended beyond construction. We optimized the sequence and integration of 176 complex systems, facilitated smooth transitions into commissioning, and supported CQV (Commissioning, Qualification, Validation) processes. We also promoted transparent communication and visual management across all 10 technical teams, which helped reduce bottlenecks and align decisions with real-time conditions.

The training and certification of 180 team members in Lean practices helped embed a unified mindset, ensuring Lean wasn’t simply implemented—it was institutionalized.

Lean Construction process during Parliament Hotel Dublin refurbishment
construction guy

Managing Director

Get In Touch

[custom_captcha_img]

Looking for implementation and support for your project?

What is 4 + 9?

Get In Touch

What is 1 + 1?

Contact For 2 or 3 Day Training

What is 7 + 2?

Contact us below for more information on this course

[What is 6 + 1?
Seraphinite AcceleratorOptimized by Seraphinite Accelerator
Turns on site high speed to be attractive for people and search engines.