Executive Summary
In the competitive healthcare industry, maintaining efficient and up-to-date production systems is critical for ensuring product quality and compliance with regulatory standards. This case study explores a project undertaken by Keller Technology to update a complex production system for an international healthcare company.
The project involved substantial control system and electromechanical modifications as well as the addition of flexibility to accommodate additional product SKUs. Due to the client’s limited internal engineering resources, Keller was tasked with providing a comprehensive solution. The design phase was driven by customer feedback, insights from production and maintenance teams, and executed in collaboration with the client’s engineering group.
Following successful redesign our company built and delivered 27 updated systems to the client’s global production facilities. This case study highlights Keller Technology’s capabilities in system redesign, manufacturing, and global deployment.
Client Description
Our client is a major player in the global healthcare industry, with a network of production facilities spread across multiple continents. Their products are essential to healthcare providers worldwide, and their manufacturing processes must meet the highest standards of quality and efficiency. The client’s goal was to modernize their production systems to enhance operational efficiency and ensure consistency across their global facilities.
Project Goals and Objectives
The primary goal of the project was to update the design of the client’s production system, focusing on controls and electromechanical modifications. Specific objectives included:
- Developing new electromechanical designs for various points within the production system.
- Replacing obsolete commercial components with readily available items.
- Accommodation of the ability to run new product SKUs on the production line.
- Ensuring the updated production systems were compatible with existing product SKUs currently being produced on the systems.
- Obtaining ~10% improvement in production throughput.
- Building and delivering 27 systems for deployment across the client’s global facilities.
Challenges Faced
The project presented several challenges, including:
Technical Challenges
The production system redesign involved significant electromechanical updates and revised controls due to obsolescence, and the addition of new SKUs to the production process. Ensuring compatibility with the client’s existing systems was critical.
Logistical Challenges
Coordinating the production and delivery of 27 systems to various global locations required meticulous planning and execution, especially given the tight timelines after the initial production system approval.
Operational Challenges
Ensuring that the updated production systems could be seamlessly and quickly integrated into the client’s production facilities without disrupting ongoing operations.
Solution and Implementation
Our approach to the project involved several key steps:
Production System Redesign
Collaborating closely with the client, our engineering team developed new designs for the production system. This process involved reviewing the client’s “wish list”, listening to the voice of the customer – incorporating suggestions from production and maintenance employees. The redesign also required replacing commercial items that had become obsolete since the previous build and accommodating several new product SKUs on the production lines. Extensive changes, including software, necessitated drafting of a revised Functional Requirements Specification (FRS). Validation protocols and test scripts for Computer System Validation (CSV) were revised.
Prototyping and Testing
Certain designs required proof-of-concept prototyping, and prior to full-scale production, a complete prototype system was built and rigorously tested to ensure it met all performance criteria. The initial production system was subjected to a Factory Acceptance Test (FAT), and upon approval, we were tasked with completing the remaining systems as quickly as possible.
Manufacturing
Once the design was finalized and approved, we proceeded with the production of 27 systems. Our manufacturing process emphasized precision and strict quality control to ensure each system met the client’s specifications. Following an initial ramp period, systems were completed at a cadence of 1-2 per month.
Global Delivery
The fully tested production systems were carefully crated and shipped to the client’s production facilities worldwide. Our logistics team coordinated with local partners to ensure smooth delivery and installation assistance was provided by Keller. IQ, OQ, and PQ protocols were executed for each production system.
Client Satisfaction
The project was completed successfully, with all 27 systems delivered to the client’s global facilities on time, within budget, and meeting all reliability and performance criteria.
Lessons Learned
Key takeaways from this project include:
- The importance of close collaboration with the client and listening to feedback from all stakeholders, including production and maintenance teams.
- The need for meticulous planning and coordination, particularly when dealing with global logistics and multiple delivery locations.
- The value of rigorous testing and quality control measures throughout the redesign, prototyping, and manufacturing process.
Multiple Builds of Advanced Automation Systems
The successful completion of this project underscores our expertise in system redesign, manufacturing, and global deployment. Our ability to manage complex technical challenges, incorporate customer feedback, and deliver high-quality production systems on a global scale has strengthened our reputation as a trusted partner for international clients in a variety of industries.
Contact Keller Technology
Are you looking for advanced automation for your production system? Whether your company is in search of custom machinery, contract manufacturing or precision fabrication, reach out to Keller Technology today.