On this interview, NewsMedical talks to Cerba’s Lukasz Wulnikowski concerning the energy of automation and the way it has drastically modified the best way they method equipment constructing traces.
What motivated the automation of your kit-building course of, and the way has it elevated effectivity and accuracy?
We acknowledged the significance of considering outdoors the field to advance our operations and decided that leveraging present technological developments could be extremely useful. On the similar time, we stay dedicated to making sure the best high quality in our merchandise.
Due to the implementation of RFID tags, we’ve got achieved 100% accuracy, successfully eliminating human error. Moreover, by dividing manufacturing into discrete steps at every workstation, we’ve got doubled our effectivity. This streamlined course of reduces complexity for our group, making duties easier and smoother to execute.
How has automation impacted your kit-building operations? Might you please present some examples that display this influence?
Manufacturing planning has turn into a lot simpler and extra correct. High quality points have been mitigated by utilizing superior expertise and decreasing the variety of meeting actions in comparison with the earlier course of, leading to elevated satisfaction amongst all group members.
Beforehand, the standard management course of concerned visually inspecting all parts in a equipment field and scanning labeled parts with a hand barcode scanner to populate an Excel file that indicated whether or not the right labels have been scanned.
A equipment field containing pre-labeled RFID parts is now scanned robotically inside 1-3 seconds after passing via two antennas. If all parts are current, the equipment will probably be sealed; in any other case, the equipment will probably be rejected, and the road will cease to pressure customers to take away the defective equipment.
Picture Credit score: Gorodenkoff/Shutterstock.com
How does automation elevate the bar for equipment high quality, and what challenges did you face throughout implementation?
The standard of our equipment merchandise has reached a powerful 100 % correctness, consistency, and accuracy. This achievement is made attainable by integrating superior software program with a conveyor belt system that includes three workstations, every devoted to a selected job. RFID labels and a monitoring station (troubleshooter) present a complete overview of the complete course of, successfully eliminating human error.
Our course of is designed to halt manufacturing every time a discrepancy is detected, requiring rapid operator intervention to take away and proper any defective kits. This ensures that solely compliant kits proceed via the manufacturing line.
To satisfy high quality requirements and guarantee compliance with GxP (Good Apply) laws, we undertook a rigorous validation course of. As a result of complexity of the system, we established a devoted group to meticulously doc and file each piece of apparatus and every step of the method, guaranteeing full traceability.
Regardless of the quite a few challenges and time-consuming nature of this venture, the dedication of all concerned events enabled us to efficiently full and ship this extremely efficient manufacturing line.
How do you deal with technical points with automated tools to make sure clean operation?
We’ve every day and weekly check-ins scheduled. Our group members are educated to scrub and preserve each bit of apparatus. We even have SLAs (Service Degree Agreements) with our distributors, which give very fast response instances starting from 8 to 24 hours.
Are there any upcoming improvements or developments that you’re significantly enthusiastic about?
We plan to develop the variety of kits on our automated line and introduce pre-labeling to reinforce effectivity. Moreover, we’re shifting in direction of digitalizing our processes. Considered one of our key ongoing initiatives is instantly associated to the equipment line and goals to supply each us and our clients with a complete overview of all orders, kits, samples, and storage. This method will provide real-time visibility 24/7.
On the similar time, we’re exploring concepts to double our equipment line manufacturing capabilities via additional enhancements. With these developments, 2025 guarantees to be an thrilling 12 months filled with alternatives for development and innovation.
Cerba Analysis – Equipment Constructing – Rijswijk
Video Credit score: Cerba Analysis
How has automation reshaped your workforce? What coaching and growth applications are in place to empower workers?
Personnel have reported a extra organized and systematized workflow with improved job division. Regardless of the elevated manufacturing capability, workers haven’t felt the necessity to work tougher or quicker, as their workloads stay unchanged as a result of environment friendly course of design.
To combine everybody into the brand new course of, we created new roles and added some small duties to the group’s duties. This helped join all group members to the up to date workflow.
We developed detailed work directions protecting each the processes and the tools. Every worker obtained complete theoretical and sensible coaching on these paperwork, together with hands-on coaching for every workstation. Moreover, we extremely worth all suggestions obtained and can use it to information future course of enhancements.
In what methods does automation assist to scale back waste and maximize useful resource utilization?
Going paperless is the best way to go, and our upcoming dashboard will take away the necessity for bodily doc creation. Every thing will probably be digitized, so after every manufacturing run, we are going to generate a file that’s robotically and digitally managed, eradicating the necessity for printing or signing.
We’ve additionally upgraded one in every of our equipment labels to a sealing label that features complete info and a barcode. In lots of instances, even the requisition kind for a equipment will probably be changed by a digital model. Nevertheless, as a result of world distribution of our merchandise, some kits will nonetheless require a paper requisition kind.
What distinguishes your automated processes from different organizations? How do you’re employed with shoppers to create tailor-made automated options?
We’re the one firm (so far as I do know) that gives automation in equipment manufacturing and ensures 100 % high quality on every equipment. RFID labels are vital on this case, as they’re an innovation that’s not generally used.
We’ve encoded an entrepreneurial method into our DNA. We already provide a custom-made resolution known as “white glove logistic companies.”
Our line means that you can simply design kits, labels, and knowledge that seems on the equipment itself (or a custom-made sealing label). Outdoors of the equipment line, we provide varied forms of custom-made containers.
How do you keep on high of the most recent automation tendencies and applied sciences in an effort to drive innovation in your position?
I’m a robust advocate of steady enchancment. After implementing the road, my group and I’ve already recognized additional enhancements to optimize it whereas sustaining the best high quality requirements.
I’m additionally excited concerning the potential of future AI developments. The probabilities that AI can provide, each for enhancing the equipment line and for streamlining every day duties and inventory management, are extremely promising. We live in thrilling instances the place innovation is aware of no bounds.
In regards to the speaker
Lukasz Wulnikowski is Manufacturing & Provides Supervisor for Cerba Analysis Netherlands. His sturdy knack for taking accountability, not just for his personal duties but in addition for the individuals he collaborates with, coupled along with his analytical capabilities, have pushed him to seek out structured and arranged options, simply figuring out and addressing errors or areas for enchancment.Â
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About Cerba Analysis
For over 35 years, Cerba Analysis has been setting the business normal for exemplary scientific trial conduct. Right this moment, throughout 5 continents, with a concentrate on precision drugs, we’re altering the paradigm of the central lab’s position in complicated scientific analysis.
From protocol inception via growth and to market, our passionate consultants ship the best high quality specialised and personalised laboratory and diagnostic options. Companion with us for essentially the most environment friendly technique to actualize your biotech and pharmaceutical merchandise sooner and enhance the lives of sufferers worldwide.
