Genzyme Case Study

It Had to Be Perfect, the First Time

Genzyme Case Study

It Had to Be Perfect, the First Time

Sanofi Genzyme (case study heading image)

Genzyme Project Highlights

  • Two Biomanufacturing Facilities
  • Boston, MA and Framingham, MA
  • 2009: Unprecedented effort to sanitize the Allston Landing Plant and rebuild operating procedures
  • 2009: Applied top-to-bottom restoration approach to new Framingham facility
  • Maintained 100% right-first-time metrics, helping to end consent decree one month ahead of schedule
  • New Framingham facility approved by FDA and EMA in January 2012
Genzyme Case Study - It Had to Be Perfect, the First Time
Sanofi Genzyme (case study heading image)

Genzyme Project Highlights

  • Two Biomanufacturing Facilities
  • Boston, MA and Framingham, MA
  • 2009: Unprecedented effort to sanitize the Allston Landing Plant and rebuild operating procedures
  • 2009: Applied top-to-bottom restoration approach to new Framingham facility
  • Maintained 100% right-first-time metrics, helping to end consent decree one month ahead of schedule
  • New Framingham facility approved by FDA and EMA in January 2012

The entire biopharmaceutical industry was watching. As were the regulators, investors, and most importantly, the patients who depended on the life-saving drugs that would soon be in short supply. This was 2009 when Genzyme confirmed that the decreasing yields it was tracking of two drugs made at its Allston Landing Plant in Boston was the result of viral contamination.

What happened next was widely documented in the media. Genzyme suspended production in Allston of Cerezyme® for Gaucher disease and Fabrazyme® for Farby disease and began an unprecedented effort to sanitize the plant and rebuild not only its operating procedures but also public confidence, ultimately working under a consent decree.

Concurrently, Genzyme was planning to expand its biomanufacturing facility in Framingham, Massachusetts. And while there was no viral contamination in Framingham, the company made the strategic decision to apply its top-to-bottom restoration approach there as well.

In that effort, Genzyme engaged ICQ to develop a new commissioning and qualification program reflecting the latest best practices, informed by the contemporary regulatory frameworks promulgated by both the U.S. Food and Drug Administration (FDA) and the European Medicines Agency (EMA).

“As Senior Director of Engineering, I was responsible for implementing a new commissioning and qualification program to comply with the consent decree remediation requirements and support our strategic capital program.”

Jim Rice, Former Senior Director, Facilities and Engineering, Genzyme

“Ultimately, ICQ Consultants produced extraordinary results by maintaining 100% right first-time metrics, helping to end the consent decree and completing all assigned scope one month early.”

Jim Rice, Former Senior Director, Facilities and Engineering, Genzyme

“Ultimately, ICQ Consultants produced extraordinary results by maintaining 100% right first-time metrics, helping to end the consent decree and completing all assigned scope one month early.”

Jim Rice, Former Senior Director, Facilities and Engineering, Genzyme

For nearly a year, a six-person team from ICQ, led by company president Michael Bogan, worked closely with Genzyme’s engineering and quality teams to build and deploy a new program. Nothing was taken for granted. The standard set by ICQ was simultaneously simple and intense— get it 100 % right, the first time, in all cases.

After months of collaborative development, ICQ deployed the Commissioning and Qualification program on Genzyme’s new Cell Culture Process Train and associated utility improvement project.

The new Framingham manufacturing facility was approved by the FDA and the EMA in January of 2012. The first batch of Fabrazyme made there shipped in March of 2012.

“Everyone understood what was at stake in this project. The resolute commitment of the Genzyme team to succeed and get patients the medicine they need was essential to ICQ’s ability to help.”

Michael Bogan, President, ICQ