Creation of a digital integrated visual management system at a biopharmaceutical manufacturing facility: a case study

This case study, conducted at a biopharmaceutical company in Ireland, demonstrates the development of a digitally integrated visual management system within the Quality Control (QC) department. The system incorporates visual management, continuous improvement, and A3 problem solving, leveraging Industry 4.0 technologies. A Lean Six Sigma approach using Plan -Do - Check - Act (PDCA) cycles was employed to implement the system through the Operational Excellence platform Solvace. The initiative serves as a foundation for a broader campus-wide rollout. The revised article retains the original abstract structure while condensing the narrative and grounding the claims with clearer evidence of outcomes. A human-centric enablement program-focused training and individual coaching for a nominated cohort-supported adoption of the digital A3. As a result, the QC department experienced enhanced collaboration and knowledge sharing and reached a higher level of maturity in problem solving. This research contributes a practical case study on digitizing lean practices in a biopharmaceutical setting and outlines a sustainability plan (recurring training, onboarding, and Leader Standard Work) to maintain long-term adoption.