Global QC Instrument Compliance and Cybersecurity Remediation – Top Quality Initiative

Context and Challenge

One of the world’s leading independent biotechnology companies faced a major compliance challenge with cybersecurity vulnerabilities across its global Quality Control (QC) laboratories. A comprehensive vulnerability assessment revealed that 93% of 596 benchtop systems were operating on outdated systems or unsupported software, creating over 6,300 security vulnerabilities.

Further, these instruments were not consistently connected to the Manufacturing (MFG) network, limiting centralized oversight, patch management, and data backup. The fragmented environment increased the risk of malware propagation, production downtime, and compliance issues.

USDM Solution

USDM Life Sciences partnered with the biotech company’s Quality, IT, and Global Asset Management teams to implement QC Instrument Remediation a global initiative to modernize, migrate, and secure the QC instrument landscape.

Strategic Implementation:

• Asset Classification and Risk-Based Remediation:
  • Part 1: Replacement of ~100 instruments.
  • Part 2: Upgrade of ~450 instruments’ operating systems.
  • Part 3: Migration of ~200 instruments to the secure Manufacturing network.
• Platform Modernization:
  • Upgraded Empower CDS to FR5.
  • Migrated LMES and CIMS to Biovia releases.
  • Integrated all systems into a segmented, Cybersecurity compliant Manufacturing network.
• Centralization and Agile Enablement:
  • Centralized validation and migration packages developed and implemented in the company’s Application Lifecycle Management system.
  • Implemented First-in-Family (FiF) pilots across all sites to accelerate rollouts.
  • Enabled electronic validation and document routing.
• Security and Resiliency Enhancements:
  • Deployed dual data centers per site.
  • Installed endpoint lockdowns, firewall protections, and role-based access controls.
  • Integrated Nozomi intrusion detection and CrowdStrike for malware protection.
• Global Program Governance:
  • Cross-functional teams with site-specific project leads, technical SMEs, and global coordination ensured cohesive execution.

Quantified Outcomes and Impact

• Dramatically reduced cybersecurity risk by cutting benchtop system vulnerabilities by 95%, lowering exposure from over 6,300 to under 300.
• Achieved enterprise-grade compliance with over 95% of systems supported, secure operating systems—up from approximately 70%.
• Fully modernized infrastructure across all five global manufacturing sites, plus AWS and sandbox environments—up from zero upgraded platforms.
• Strengthened system resilience with the deployment of more than 75 new servers aligned with modern security and reliability standards.
• Standardized validation across operations with 24 lab environments fully qualified and compliant with the latest software versions.
• Accelerated adoption through innovation by qualifying First-in-Family (FiF) instruments at each site, enabling rapid deployment across similar systems.
• Secured strategic investment of over $10M through executive sponsorship, enabling full program mobilization and long-term lifecycle alignment.

Operational Benefits:

• Significantly minimized downtime risk.
• Enabled centralized, scalable patch management.
• Improved audit readiness and system traceability.
• Empowered inter-site collaboration and knowledge-sharing.

Strategic Takeaways:

• Centralization Drives Consistency and Scale – Reusable validation and deployment templates enabled efficient rollouts across multiple geographies while reducing site-specific overhead.
• Cyber Resilience Requires Organizational Alignment – Sustainable transformation occurred at the intersection of people, process, and platform—with IT, Quality, and Operations collaboratively managing risk.
• Meta-Skills Strengthened Change Readiness – Team members developed preparation, discernment, and collaboration capabilities essential for ongoing transformation.
• Contextual Thinking Enabled Scalable Strategy – Using sociological approaches, the project accounted for site-specific constraints, technical history, and operational culture to craft a high-fidelity, transferrable solution.
• Agile Delivery Paired with Local Empowerment Is Key – Rapid learning loops via FiF pilots and validation bundles accelerated adoption while enabling local ownership and adaptation.

USDM can help your organization achieve cyber resilience by delivering secure, compliant, and scalable solutions tailored to the unique needs of regulated environments. Contact us to learn more.