MSD Biotech Dublin

In support of its mission to manufacture breakthrough medicines in Ireland for patients around the world, MSD Biotech wanted to ramp up production capacity at its Dublin Drug Substance Facility for one of its key oncology treatments.

Building on the deep expertise developed during the initial construction of the facility, Jacobs was uniquely positioned to deliver the upgrade and partnered with MSD Biotech to significantly increase capacity at the state-of-the-art facility in Swords, Co. Dublin. 

Our previous experience empowered the project team to forge strong relationships with the client from the outset and to work as an integrated team as we delivered Engineering, Procurement, Construction Management and Validation (EPCMV) services.

Underpinning this partnership approach was a project delivery method that saw an overlap of design, supply chain procurement, construction, commissioning and qualification activities. Close working relationships meant that the design and construction teams worked seamlessly to overcome any delays to long lead times for specialist equipment. This approach was especially helpful in mitigating supply chain risks caused by external factors ahead of the shutdown period between January and March 2022.

As there could be no interruption to the facility’s operations during the construction phase, work had to be completed within these pre-determined shut-down periods and to the highest safety and quality standards, despite a fast-tracked schedule. With the emergence of COVID-19, leveraging new techniques, safety measures and digital technology became paramount.

Tapping into technology to put on-site safety first 

The design team was located remotely and deployed 3D modelling to deliver each aspect of the project. To minimize the number of people on-site, the project team used Holo Lens VR headsets to facilitate remote reviewing of project work, while the digitisation of close to 1,200 contractor turnover packs meant the project flowed seamlessly. 

To mitigate risks and support on-site safety while ensuring there was no impact on GMP operations, our team designed a specific Safe Plan of Action (SPA) and clean build protocol which was rolled out to all project members in advance of construction works. The introduction of unique project QR codes facilitated on-site electronic check-ins, COVID checks and site and quality observation reports. 

These solutions are now an integral part of our approach, ensuring projects are delivered safely and within accelerated timelines. And, thanks in part to our approach, upon completion, the Dublin Drug Substance Facility project achieved a best-in-class safety performance with no recordable instances during the 350,000 hours worked on site.

Our deep expertise and lean, integrated approach meant that we were able to overcome complex, broad challenges. Ultimately, our work means that patients worldwide will receive potentially life-changing medicine faster.

This project was shortlisted and won the Fit Out or Refurbishment Over €10m Category of the 2024 Irish Construction Excellence Awards.