Overview
A rapidly growing Cell & Gene Therapy company was scaling up its cell culture capacity at a facility located outside a major biopharma hub. However, this expansion came with significant challenges, particularly in finding local engineers with the necessary automation and GXP experience. As a result, the company faced high travel costs, with engineers commuting over four hours from Catalyx PCA HQ.
To address these challenges, we provided immediate support for the facility’s short-term ramp-up and ensured long-term stability after manufacturing began.
Challenge
Skilled Workforce Shortage and High Travel Costs
As a rapidly expanding Cell and Gene Therapy company, the facility faced a critical challenge—there was a shortage of local engineers with the required automation and GXP experience. This skills gap led to a reliance on engineers commuting over four hours from Catalyx PCA HQ, resulting in significant travel costs and logistical inefficiencies.
Solution Approach:
Establishing a Sustainable Local Engineering Presence
To overcome the challenges of a limited local talent pool and high travel costs, we implemented a Managed Services Agreement and established a local office to create a long-term, sustainable support system. Our approach focused on leveraging local expertise, reducing attrition, and enhancing workforce development to ensure the facility’s success.
Implementation Strategy:
Deployed Subject Matter Experts (SMEs) for Immediate Knowledge Transfer
We relocated two highly experienced SMEs to the site to establish a foundation of expertise, providing on-the-ground support, facilitating knowledge transfer, and streamlining operations.
Built a Local Engineering Workforce
We hired local engineers to provide foundational engineering support, helping to establish a sustainable talent pipeline. By sourcing talent from the surrounding area, we reduced attrition often seen with relocated employees. Additionally, local hires received training in automation and GxP practices, enabling the development of a self-sufficient, skilled team over time.
Enhanced Employee Retention Through Career Development
We established an internal career path within the local support team, offering structured growth opportunities. A dedicated training and development program was implemented to upskill engineers, improve retention, and enhance service quality. By investing in continuous learning, we expanded technical capabilities and ensured long-term operational stability at the client site.
This strategic approach reduced dependence on long-distance engineers, lowered costs, and built a self-sustaining local workforce—ultimately improving operational efficiency and supporting the facility’s long-term success.
Outcomes:
Significant Cost Reduction:
Eliminated the need for long-distance commuting, reducing travel costs by approximately $1,200 per engineer per week.
Accelerated Project Execution:
Improved collaboration with onsite resources, leading to faster decision-making and more efficient project delivery.
Successful GMP Production:
Achieved Good Manufacturing Practice production at the facility within three years.
Scalable & Sustainable Support Structure:
Established a self-sufficient local workforce that supports Business-As-Usual operations while retaining critical expertise for future capital projects.
Conclusion:
By implementing a Managed Services Agreement and establishing a local engineering workforce, we successfully addressed the talent shortage and high travel costs that initially challenged the Cell and Gene Therapy company’s expansion. Our approach not only enabled the facility to achieve GMP production within three years but also created a sustainable and scalable support structure for future growth.
Through strategic talent acquisition, knowledge transfer, and employee development, we reduced operational costs, enhanced collaboration, and ensured long-term stability. The company now benefits from a self-sufficient local team, minimizing reliance on external resources and positioning the facility for continued success in a competitive biopharma landscape.