| Project Value | Duration | Teams Collaborated with | Systems Installed & Comissioned | Partners Trained & Certified |
|---|---|---|---|---|
| € 150M | 36 Months | 10 | 176 | 180 |
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.
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:
This allowed the team to maintain predictability and control throughout the delivery process.
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:
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:
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.
