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MSD Carlow Rathgal

Project – MSD Carlow Rathgal

Project Value Duration Teams Collaborated with Systems Installed & Comissioned Partners Trained & Certified
€ 0.5Bn 12 Months 6 279 250

Project Overview

The MSD Carlow Rathgal project marks a major milestone in pharmaceutical manufacturing—a first-of-its-kind, state-of-the-art facility dedicated to the production of next-generation oncology biologics. Valued at €0.5 billion, this ground breaking initiative was successfully delivered within a demanding 12month timeline.

The facility’s construction phase created 700 critical roles, significantly boosting the local economy and skills base. The project involved the full build and commissioning of a highly advanced biologics plant. This included the integration of 27 complex systems and key equipment such as:

  • Medium & Low Voltage (MV/LV) Modules

  • Chilled Water (CHW) Generation Skids

  • Water for Injection (WFI) Modules

  • Work In Progress (WIP) Skids

  • Autoclaves

  • Advanced Fillers and Isolators

  • Inspection Machines

  • Steam Boilers

Each of these systems required precise installation, testing, and commissioning to meet the stringent operational standards for oncology treatment production.

An extensive upskilling program supported the project’s execution, with 250 partner personnel trained and certified in best practices to ensure quality and consistency across all systems and processes.

Our Project Scope (Construction & Commissioning)

Lean Touch Solutions led the implementation of a robust Lean Construction program during both the construction and commissioning phases. With a tight timeline and a complex scope, embedding Lean principles was essential to meet milestones and manage system integration risk.

Our work focused on:

  • Streamlining installation and commissioning workflows

  • Reducing delays and non-value-added tasks

  • Facilitating seamless collaboration across 6 key teams

  • Creating a proactive, problem-solving environment

By applying Lean practices across all areas—from planning to execution—we helped maintain momentum and ensure high-quality delivery on schedule.

Project Approach

Lean Construction Strategy:

Our approach began with the co-creation of a tailored Lean Construction Strategy, developed in close collaboration with MSD, project managers, and specialist trade partners. Securing full buy-in from all stakeholders—including client leadership and trade teams—was essential in embedding a strong, unified Lean culture.

We deployed Lean Touch Solutions’ standardised implementation framework, adapting it to the unique demands of the biologics manufacturing environment. This involved:

  • Value Stream Mapping of critical construction and commissioning processes

  • Adoption of the Last Planner® System to drive predictable workflow

  • Implementation of 5S principles to ensure well-organized, efficient workspaces

  • Coordinated Lean training for all stakeholders

The training and certification of 250 partners demonstrated our commitment to a truly holistic Lean approach—one that extended across all project stages, teams, and disciplines. This widespread capability was instrumental in achieving the project’s ambitious targets on time and with exceptional quality.

Lean Construction process during Parliament Hotel Dublin refurbishment
construction guy

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