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Cell and Gene Therapy

Scaling cell therapy operations with Binocs: Legend Biotech’s journey to efficiency

At the 2024 Binocs Community Day, James Carr, Associate Director of Supply Chain at Legend Biotech’s Raritan site, shared how Binocs helped the company transition from manual scheduling processes to a streamlined, scalable production planning system for large-scale commercial cell therapy. This transformation not only optimized operations but also enhanced Legend Biotech’s ability to deliver personalized medicines to patients effectively.

The challenge: Manual processes limiting scalability

Legend Biotech’s cell therapy operations, centered on highly individualized manufacturing processes, faced critical operational challenges:

  • Unsustainable manual scheduling: Teams managed over 60 workstations and 5000 data iterations weekly using Excel, resulting in a 20-hour workload per planner.
  • High error probability: Manual processes increased the likelihood of mistakes, risking delays in production and delivery.
  • Limited visibility: The lack of a centralized system prevented teams from optimizing resource allocation and addressing conflicts in real time.

James Carr summarized the pre-Binocs landscape:

We quickly realized that if we wanted to get to the targets we set for ourselves, Excel wasn’t going to be a sustainable approach.

The solution: Proof of concept and phased implementation

To address these challenges, Legend Biotech partnered with Binocs to implement a phased rollout, starting with a proof of concept (PoC) to pressure-test the system and demonstrate value.

  • 1. Proof of concept: Establishing the foundation

    Legend Biotech conducted a PoC in 2023 to evaluate Binocs’ ability to handle the complexities of cell therapy production:

    • Reduction in manual processes: The PoC eliminated 60% of manual steps and replaced most Excel schedules.
    • Improved scheduling accuracy: Binocs enabled resource allocation based on qualifications, critical for compliance in this regulated industry.
    • High user requirement attainment: The system met 87% of predefined user requirements out-of-the-box.

    “We were thrilled with those metrics,” James shared. “To achieve that level of alignment without a massive implementation was a great start.”

  • 2. Phase 1: Transitioning to a single source of truth

    Building on the PoC, Legend Biotech deployed Binocs as the single source of truth for scheduling:

    • Streamlined scheduling: Operators gained a consolidated view of schedules, enabling efficient resource allocation and conflict resolution.
    • Hypercare model: A three-week support period post-go-live ensured smooth adoption and operational stability.

    James highlighted the milestone: “The majority of Excel schedules have now been decommissioned, and we are using Binocs as that single source of truth.”

  • 3. Preparing for scalability through change management

    Legend Biotech emphasized preparation and scalability during the implementation to ensure long-term success:

    • Superuser network: Dedicated superusers were embedded in each functional team to support operations and share Binocs expertise.
    • Data and engineering controls: Significant effort was invested in master data preparation to optimize scheduling accuracy and scalability.
    • Change management: Teams transitioned from Excel workflows to the Binocs platform, supported by tailored training programs to ensure adoption.

    “The system is only as good as the inputs you put into it, and the time you spend investing in it,” James noted.

By prioritizing robust data preparation and training, Legend Biotech ensured a strong foundation for future phases.

The results: Optimizing operations for scale

The implementation of Binocs delivered measurable benefits for Legend Biotech’s Raritan site:

  • Enhanced operational efficiency: Manual scheduling was replaced with automated processes, saving time and reducing errors.
  • Improved resource utilization: Teams could allocate analysts and equipment dynamically, ensuring maximum slot utilization for patient-specific therapies.
  • Real-time conflict resolution: The ability to track and mitigate scheduling conflicts in real time reduced delays and optimized workflows.

“With Binocs, we can track and resolve conflicts by process or operation in real time, maximizing our slot utilization,” James explained.

What’s next: Scaling across the network

With Phase 1 complete, Legend Biotech is focusing on:

  • Phase 2: SAP integration: Automating data inputs to further reduce manual interventions.
  • Phase 3: MES integration: Providing real-time manufacturing data to Binocs for even greater scheduling precision.
  • Network-wide rollout: Expanding the system to additional nodes and sites based on best practices established at Raritan.

As James concluded, “We’ve realized the importance of digitization in the cell and gene therapy industry. Solutions like Binocs are critical to scaling effectively and delivering for our patients.”

Curious to hear more?

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