Continuous Improvement & System Development project

Client: Seqirus Global Manufacturing Leader

Led by: Lee Bellis, GEMBEX Founding Consultant

At Seqirus, Lee managed plant shutdowns and championed autonomous maintenance, ensuring safe, efficient execution. He led LEAN and Kaizen projects to boost OEE and site safety, standardized maintenance job plans, and supported reliability systems like RBM and TPM.

Lee developed technical training programs, promoted CBM tools, and integrated systems such as Maximo for continuous improvement. His efforts strengthened safety and cGMP culture, improved equipment reliability, and enhanced team capability through structured processes and training.

Gold text that reads 'Objectives' with a black background and three sparkles or stars.

  • Plan and execute plant shutdowns to ensure safe, efficient, and compliant maintenance.

  • Develop and improve maintenance systems (MA, RBM, TPM, LEAN) for reliability and compliance.

  • Promote safety and cGMP culture across all maintenance and operational activities.

  • Enhance technical capability through training programs and CBM tool adoption.

  • Lead continuous improvement initiatives to boost OEE and site safety.

  • Implement and sustain workplace management systems for better communication and team effectiveness.

Gold glittery stars behind the text 'Actions Taken' on a black background.

  • Designed, implemented, and managed shutdown plans, coordinating cross-functional teams.

  • Acted as site autonomous maintenance champion, embedding operator asset care practices.

  • Led LEAN/Kaizen projects targeting OEE and safety improvements.

  • Supported maintenance appraisal process as a subject matter expert.

  • Developed and disseminated technical training programs for maintenance and operations staff.

  • Standardized maintenance job plans and improved task consistency.

  • Facilitated use of CBM tools and integrated systems like Maximo, Shopware, PCS for performance tracking.

  • Promoted HSE compliance and cGMP standards through audits and coaching.

The image contains the word 'Results' in gold font with three sparkling star-like graphics on a dark background.

  • Successful shutdown execution with minimal downtime and zero safety incidents.

  • Improved equipment reliability and compliance through RBM and TPM practices.

  • Increased OEE via targeted LEAN projects and operator asset care initiatives.

  • Enhanced team competency through structured technical training programs.

  • Established standardized maintenance tasks, reducing variability and improving efficiency.

  • Strengthened safety culture and cGMP adherence across maintenance operations.

  • Improved communication and visibility through workplace management systems.

Gold-colored text 'Lessons & Legacy' with a sparkle design on a dark background.

Early planning and cross-functional alignment are critical for shutdown success.

  1. Standardization and visual management drive consistency and reduce errors.

  2. Continuous training and skill development are essential for sustaining improvements.

  3. Embedding autonomous maintenance empowers operators and reduces reactive work.

  4. Data-driven decision-making (via CBM tools and Maximo) enhances reliability and compliance.

  5. Culture change (HSE and cGMP focus) requires ongoing reinforcement and leadership visibility.