2012 Facility of the Year Awards Program Names Merck's Vaccine Bulk
Manufacturing Facility (VBF) Program of Projects as Overall Winner
TAMPA, Fla., Nov. 12, 2012
TAMPA, Fla., Nov. 12, 2012 /PRNewswire-USNewswire/ --ISPE announced during
the Plenary Session at its 2012 Annual Meeting in San Francisco, Calif. USA,
that Merck's Vaccine Bulk Manufacturing Facility (VBF) Program of Projects is
the Overall Winner of the 2012 Facility of the Year Awards (FOYA) program.
Faced with a projected production shortfall for the Varicella product
franchise, Merck responded by delivering the Vaccine Bulk Manufacturing
Facility (VBF) Program of Projects in Durham, North Carolina, USA. The
214,000-square-foot facility was built in record time and doubled the output
of the vaccine used for Chicken Pox and Shingles.
The Merck Team used an innovative hybrid modular construction strategy that
maximized off-site fabrication and equipment testing. Interesting for this
application, the integrated construction execution strategy decoupled the
design and construction of the building envelope and shell from interior
process components, enabling parallel processes – as soon as the building
shell was dried in and elevated slab poured, modules were installed
simultaneously above the slab. This resulted in the ability to establish two
independent work zones (above and below the slab) and saved five months on the
The team was organized as "One Team" with all members co-located in an
integrated partnership. LEAN Six Sigma principles were used throughout the
project and resulted in an accelerated transfer of systems to operations.
Integrating more than 200 lessons learned from the existing facility and
process, the facility was delivered 40% faster than industry benchmarks. For
this, Merck was named the 2012 Facility of the Year Awards Overall Winner.
More information about Merck's winning project, as well as the Facility of the
Year Awards program in general, can be found at www.FacilityoftheYear.org.
About the Facility of the Year Awards Program
Sponsored by ISPE, INTERPHEX, and Pharmaceutical Processing magazine, the
Facility of the Year Awards (FOYA) program recognizes state-of-the-art
pharmaceutical manufacturing projects that utilize new and innovative
technologies to enhance the delivery of a quality project, as well as reduce
the cost of producing high-quality medicines. Now in its seventh year, the
awards program effectively spotlights the accomplishments, shared commitment,
and dedication of individuals in companies worldwide to innovate and advance
pharmaceutical manufacturing technology for the benefit of all global
For more information, contact:
Communications Manager, ISPE
Industry Vice President, INTERPHEX
Associate Publisher, Pharmaceutical Processing
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