Work
/
High-stakes projects
A global pharmaceutical manufacturer engaged Morgan to establish a new $250M mRNA facility in Melbourne — their first in the southern hemisphere. Morgan embedded with senior leadership to navigate stakeholder pressure, build operational readiness, and support executive decision making.
Industry
Manufacturing
Pharmaceutical
Challenge
Navigating complex bio-technical regulatory requirements and cross-functional site dependencies under an aggressive timeline.
Our Service
Support to Project Delivery & Operational Readiness
Achievements
Seamless facility commissioning with 100% regulatory compliance achieved on schedule.
CONTEXT
Moderna signed a contract to establish Australia's first mRNA vaccine manufacturing operation. The Melbourne site would be the first to combine drug substance and drug product manufacturing under one roof, breaking new ground for Moderna globally.
PROBLEM
Moderna were constructing a brand new +$250 million facility in parallel with building an organisation capable of running it. They needed to recruit, stand up business functions, define processes, and navigate a highly regulated environment. All at pace and against an aggressive timeline, with a complex global stakeholders landscape.
WHAT WE DID
Morgan were onboarded within the first 15 employees. We led the operational readiness program to set up Moderna's manufacturing operations, support the facility construction and commission complex equipment. Embedded in the senior leadership team, we worked with directors to design, develop and deliver their functions. Managing the timeline and coordinating across all parts of Moderna's operations, we helped keep everyone aligned on where we were, progress being made, risks and mitigations and key next steps. We also helped the site build trust in the global network, managing global stakeholder reporting, leading global stakeholder workshops and enabling executive decision making.
THE OUTCOME
Established an operating manufacturing business from scratch. Over 100 people joined Moderna's Australian operations, key manufacturing functions were stood up (operations, quality, manufacturing, science and technology, supply chain, EHS, facilities engineering and digital).
Rapidly built the commercial manufacture maturity of complex drug products. Global stakeholders gained confidence in local leadership's ability to deliver.
It wasn't a straightforward path with perfect execution, but it was a resounding success, contributing to the diversity of Australia's economy.
Moderna and Morgan established a trusted relationship.
PROOF
Morgan was re-engaged to develop a three year strategy to expand operations at site
Moderna Australia recognised as the benchmark for global reporting by the global head of manufacturing
Site successfully completed regulatory inspections
Performance metrics demonstrated manufacturing capability
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