Challenge (Assess)

• In biologics R&D labs, daily operations were slowed by cluttered storage, scattered consumables, and inconsistent 5S discipline. Teams often spent 20–30 minutes per experiment searching for glassware, reagents, or tools. SOPs existed but were stored in binders or PDFs, rarely followed step-by-step on the bench. Compliance confidence was low, with audit prep taking 2–3 weeks of extra work.

Solution (Solution + Identify, with Co-Design)

• Instead of imposing pre-made templates, we co-designed visual systems with the R&D teams, ensuring the systems fit their workflow:

  • 5S Layouts & Lab Zoning: Teams helped mark what belonged where, creating shared ownership.

  • Shadow Boards & Labeling: Scientists identified critical tools → we designed boards around their input.

  • Visual SOP Displays: Procedures reformatted into step-by-step visuals in collaboration with QA leads.

  • Kaizen Circle™ Boards: Improvement ideas captured directly from bench-level users.

  • Knowledge Hub™ Posters: Designed with scientists, using lab-specific reminders for GMP/5S discipline.

Impact (Know Impact + Trigger Action)

• Time savings: Retrieval time for lab materials dropped from 20+ mins to under 5 mins.

• Audit readiness: Prep time reduced from weeks to <3 days, with SOPs visible at the point of use.

• Compliance: SOP adherence improved by an estimated 40%, reducing repeat errors.

• Engagement: Over 50 Kaizen ideas logged in the first quarter — 80% were team-driven, not consultant-driven.

• Culture shift: Scientists reported feeling “this is our system, not an external imposition.” Sustaining 5S became easier because the team owned the design.