Demand Requires Expansion
Challenge from the Client
Our client faced the challenge of expanding its manufacturing and packaging capacity, along with support functions, for their Line 4 Expansion Project in Spokane, Washington. The goal was to meet the growing demand for pharmaceutical products by constructing a new addition to the existing facility, specifically incorporating an aseptic fill line and supporting functions within a compressed schedule and limited budget.
Our Approach & Solution
IPS met the challenge for the Line 4 Expansion Project by improving process segregation, efficient workflow, efficient cleanroom design, and regulatory compliance, particularly in the aseptic fill line suite. This was done by identifying critical steps and potential points of contamination. Layout modifications and procedural enhancements were addressed. Bottlenecks or redundant steps and operations were also identified and removed. Overall, improved gowning procedures, material/personnel/equipment, and waste flows were achieved, incorporating process segregation, workflow optimization, and automation.
The project also incorporated a harmonious workspace where employees could thrive. The Employee Services area served as a workspace that reflected the company’s brand and identity, the thoughtful placement of collaborative spaces like meeting rooms versus open work areas, and an expansive open lunchroom with outdoor seating.
The Results
The achieved outcomes of the Line 4 Expansion Project included increased manufacturing capacity, operational efficiency, improved product quality, and regulatory compliance, especially within the aseptic fill line. The project milestones involved multiple permits, bids, and construction packages, with construction commencing by mid-Q3 2023 and final occupancy achieved by mid-Q4 2025. The project was executed collaboratively as a modified Design-Assist delivery model involving transparent engagement with the General Contractor (GC) and select trade partners.
