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MSD Carlow Expansion

MSD Carlow Expansion

Project Value Duration Teams Collaborated with Systems Installed & Comissioned Partners Trained & Certified
€ 0.5Bn 24 Months 10 200 300

Project Overview

The MSD Carlow Expansion project marks a major milestone in pharmaceutical innovation and capacity enhancement. Originally established as a critical site for the launch and commercial supply of vital vaccines, biologics, and small molecule drug products, the Carlow facility has played a foundational role in MSD’s global operations. With this €0.5 Billion expansion, MSD demonstrated its continued commitment to Ireland by investing in cutting-edge facilities, built over a 24-month period.

The project significantly upgraded the site with new state-of-the-art production areas, advanced laboratories, and large-scale, temperature-controlled warehousing units. A defining feature of the MSD Carlow Expansion project was the successful integration of over 200 complex systems, requiring the coordinated effort of 10 specialized teams. This effort was paired with a large-scale upskilling program, with 300 partner personnel trained and certified in key methodologies to ensure high-quality execution and alignment.

Our Project Scope (Construction & Commissioning)

Lean Touch Solutions was engaged to lead the implementation of Lean Construction methodologies throughout the construction and commissioning phases. Our objective was to ensure the successful, on-time delivery of new facilities with minimal disruption to existing operations. Applying Lean thinking was critical, particularly due to the complex interfacing between live environments and new infrastructure.

Key priorities included optimizing workflows, improving coordination among the 10 collaborating teams, and integrating all 200 systems efficiently. Our Lean approach focused on reducing waste, increasing transparency, and fostering a collaborative environment to maintain operational continuity.

Project Approach

Lean Construction Strategy:

From project inception, we worked closely with MSD’s site leadership, project management teams, and trade partners to develop a bespoke Lean Construction Strategy tailored to the unique challenges of expanding an operational pharmaceutical site. The strategy addressed interface risks and emphasized alignment between construction, commissioning, and ongoing site activities.

This was implemented using Lean Touch Solutions’ proven and standardized Lean Construction Implementation framework. Tools such as the Last Planner® System (for reliable scheduling), Value Stream Mapping (for process efficiency), and 5S (for workplace organization) were core to our delivery model. The training and certification of 300 partners further embedded these practices across the workforce.

This structured, collaborative, and standardized Lean approach was essential to delivering the MSD Carlow Expansion project on time—successfully integrating new systems into live operations and supporting the site’s critical role in MSD’s global pharmaceutical supply chain.

Lean Construction process during Parliament Hotel Dublin refurbishment
construction guy

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