Presentation on theme: "“Innovation to Legacy Manufacturing”"— Presentation transcript:
1 “Innovation to Legacy Manufacturing” Jennifer NockDecember 2009Hello I’m Jenny Nock and today I’m going to tell you about my knowledge transfer partnership, but firstly I’m going to tell you a little about me.
2 Engineering Product Design BSc Hons About MeEngineering Product Design BSc HonsJuly 20072.5 yrsJennifer NockOct 2008 toOct 2010In 2007, I graduated from Aston University with a 1st class honours degree in Engineering Product design. I then moved to Cornwall seeking sun and sand and have been living in Charlestown for the last 2.5 years.I started as a KTP associate back in October 2008, in a collaboration between Plymouth university and Becton Dickinson in Plymouth, and earlier this year in I got married. So it’s been quite a busy year!May2009
3 Agenda About Becton Dickinson Why KTP? The KTP Project Aim Progress & AchievementsBenefitsConclusionQuestion TimeAnyway, enough of that, and lets get back to telling you about the knowledge transfer partnership. The agenda for this session is as follows;I’m going to tell you a little about BD and their main product Vacutainer,Why the KTP was establishedThe Project AimThe achievements to dateThe benefits to the partiesAnd a ConclusionIf you have any questions please save them all up, and ask me at the end.
4 BD Plymouth Pre-analytical medical industry Manufacture a variety of evacuated blood collection systems – Vacutainer®Manufacture millions of units per weekUK and European MarketBD Plymouth are in the pre-analytical medical industry and predominantly manufacture Vacutainer’s, which are evacuated blood collection tubes. They manufacture millions of units per week and supply a firm customer base for the UK and European markets.
5 Vacutainer Tubes Plastic Tubes Injection Moulded Additive added to tubesTubes evacuated & sealed with lidsTubes LabelledBlood Sample TakenTubes Packed & SterilizedTubes DispatchedI just want to give you an overview of the production of the vacutainer tubes and use, so that the rest of this presentation makes sense.The tubes manufactured by injection moulding. Additives may then be added to the tube to aid with the blood analysis. The tubes are evacuated to enable the correct amount of blood to be drawn into the tube, and are sealed. The tubes are then labelled, packed and sterilized. The tubes are dispatched and the end customer uses the tubes to take blood samples from patients.
6 Why KTP?Strong market position is maintained by continuous production improvementsRequirement to understand some specific manufacturing processes in order to improve them.BD lack experience and knowledge to fully understand these processes.BD’s strong market position is maintained by continuous production improvements, and cost reduction whilst maintaining high quality standards.BD sought to understand some specific manufacturing processes so that they were in the position to improve them.They however lacked the experience and knowledge to fully understand these processes.A two year KTP between BD and Plymouth university was established to draw on the expertise and resources from the ‘School of Marine Science and Engineering’These capabilities accessed through KTPExpertise and Resources from: School of Marine Science and Engineering
7 (*amendment from initial project plan) The KTP ProjectAimTo develop, embed and disseminate a culture of applying technological innovation to advance manufacturing and efficiency improvements resulting in sophisticated production systems.ProjectsPolymer Printing* CompleteAdditive Dispense In ProgressThe aim of the KTP is to o develop, embed and disseminate a culture of applying technological innovation to advance manufacturing and efficiency improvements resulting in sophisticated production systems.There are two specific technical problems to be addressed during the duration of the KTP. The first relates to labelling the product by printing directly on the tube, and the second relates to dispensing of additive into the tube.(*amendment from initial project plan)
8 Polymer Printing Project SituationChanges to manufacture of tubes could effect ability to print on tubes.Project AimConfirm business concerns.Identify solution & develop solution to overcome potential issueCertain customers require product information to be printed directly onto the tube, as they apply their own labels. BD was concerned that if any changes were made to the manufacture of the plastic tubes, then they would be unable to print directly onto the tube.The KTP project aim was to identify and develop a solution to overcome this potential issue.
9 Tube Printing Project Progress Confirmed concernsIdentified Potential Solutions- Surface treatment best solutionNew Surface Treatment TechnologyIntegration: Tube Handling TechnologySolution CostedBusiness Case to Raise CapitalInitially the KTP confirmed these concerns surrounding the polymer printing future through research and experiments. If changes were made to the manufacture then the adhesion properties of the polymer would be affected. We then identified potential solutions to overcome these issues. These solutions were evaluated and it was concluded that surface treatment would be the best solution. There are numerous different types of surface treatment methods, some more aggressive than others. By taking to suppliers and running tests, a new surface treatment technology was identified as being the best technology for this application. In order to integrate the surface treatment onto the line we needed a method to rotate the tubes. This equipment was spec’d out and we received quotes and designs from numerous suppliers. The full solution and integration requirements were identified and costed and business case was prepared so that the capital could be raised.The project concluded in the form of a completion report detailing all the research and integration work to be carried out. When the solution is required, the company are in the position to implement the surface treatment system quickly, therefore safeguarding the business activity.Completion ReportReady for Implementation
10 Additive Dispense Project SituationAdditive to blood ratio critical!Require full understanding of process in order to improve them.Ultimate goal: Zero DefectsProject AimUnderstand Additive Dispense ProcessImprove Additive Dispense ProcessThe ratio between the additive in the tube, and the blood drawn into the tube is critical. Too much or too little additive in the tube could lead to inaccurate blood test results, and therefore mis-diagnosis of the patient.The quality of BD’s vacutainer is very high, however BD is striving for further improvement and the next step is zero defects.The KTP will assist in achieving this zero defects by focusing on understanding and improving the additive dispense process.
11 Additive Dispense Project Progress Additive added to tubesEarly stages of cause investigationDeveloping offline test rigFurther investigationEvaluate possible solutionsThe project is currently in its early stages and we are just investigating all the causes and effects for low or no fills of additive. We are also developing an offline test rig, to conduct further investigate tests and also to evaluate possible solutions.
12 Benefits Exposure to operations of manufacturing plant & manufacturing issues faced by industryPolymer Printing Research reportPotential case study for studentsRaised awareness of surfacetreatment technologiesAccess to university test equipmentAdditional resource to projectengineering departmentSpecialist resource to assistwith other projectsSolution to polymer printingUniversityCompanyAssociateFormal training: KTP and BDImproved skills: presentation, project managementProject Management Industrial ExperienceNew contacts in industry
13 Knowledge Transfer so far… Knowledge transfer limited due to project amendment.Knowledge base taken on more of a supportive role.Have been in the background assisting with ‘hot topic’ queries.
14 Knowledge Transfer Future Knowledge base to be part of a BDMore involvement rather than just reporting to.Bring the University and BD together.Culture change to BD with being able to outsource information.
15 Conclusion KTP & Projects Challenging Improved skills Developed a solution to safe guard business activity.Majority of benefits from next projectFocus is on Knowledge Transfer
16 Acknowledgements Project Manager – Mandy Bowden Company Supervisor – Larry StockmanAcademic Supervisors – Neill Hughes, and Dr Peter DysonColleagues at BD Plymouth
17 Any Questions…? Plastic Tubes Injection Moulded Additive added to tubesTubes evacuated & sealed with lidsTubes LabelledTubes Packed & SterilizedTubes DispatchedBlood Sample Taken
18 Tube and Standard Needle Assembly CannulaHubSleeveNeedle HolderVacutainer Tube