Post on 19-Jan-2017
transcript
Employee engagement through Lean driven innovation
Himanshu Parikh, Ph.D. VP, Manufacturing Operations
Roche Diagnostics Ventana Medical Systems, Inc.
The foundation of Ventana Medical Systems, Inc. (Ventana)Ventana was founded in 1985 by, Thomas Grogan, MD., Professor of Pathology at the University of Arizona.
Dr. Grogan had a vision for single, automated pathology test covering all aspects of a patient’s case and therapy to improve survivability
Created a passion for improving diagnosis and patient outcome
Developed a Culture of Accountability focused on improving the lives of all patients afflicted with cancer
Ventana at a glance• Over 1,200 employees across North America• Fully integrated commercial operations, manufacturing, research and
development in Tucson, AZ• 249 granted patents worldwide and 219 pending patents worldwide• Over 250+ diagnostics tests; world’s largest ready-to-use assay menu• 10,000+ systems installed worldwide• Products in over 80 countries with 14% annual target growth• Acquired by F. Hoffmann-La Roche in early 2008, the largest biotech
company in the world • Began Lean journey in 2001
Roche goal:One-stop shopping for anatomical pathology (AP) labs
Advanced Staining
Special Stains
Order Entry
Microtomy
Embedding
Tissue Processing / Record Time
Gross Cassette
Verification
Accessioning
Sample Transportation
Patient InPatient Out
Tele-Pathology
Advanced Image Analysis
Pathologists Review
Case Assembly
AP Labs operate an integrated workflow
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1023
Digital Slide
Scanning &
Analysis
AP lab workflow today
H&E
Sample Collection
Ventana goal: One-stop shopping for AP labs
Advanced Staining
Special Stains
Order Entry
Microtomy
Embedding
Tissue Processing / Record Time
Gross Cassette
Verification
Accessioning
Sample Transportation
Patient InPatient Out
Tele-Pathology
Advanced Image Analysis
Pathologists Review
Case Assembly
AP Labs operate an integrated workflow
1023
1023
Digital Slide
Scanning &
Analysis
Ventana solutions in the AP lab today
H&ERTD’s offerings today
Primary Staining StingingHE 600
BenchMark
Digital Slide Scanning &
Advanced Image Analysis
iScan HT
BenchMark
Sample Collection
Vantage
The Ventana portfolioDelivering testing efficiency and medical value
Pre-analyticaltissue preparation
Primary stainingH&E stain
Advanced staining SS, IHC, ISH
Workflow managementconnectivity
Customer care and consultative services
Imaging/reportingimage analysis
Single Minute
Exchange of Dye(SMED)
Total Preventativ
e Maintenanc
e(TPM)
Jidoka
Just in Time(JIT)
Visual controls
Production
Planning Process
(3P)
Process monitori
ng
5s Kanban Standard work
Heijunka
Process smoothi
ngKaizen
Lean Enterprise
The Ventana journeyBegan May 2001
> 70% of management team participated in Lean training and events
Held more than 130 Kaizen events
> 65% of employees participated in Kaizen
Reorganized Manufacturing by product teamso Self-directed work teams utilizing
Group Lead/Team Lead methodology
Kaizen-( 改善 ?), Japanese for "improvement" or "change for the best“.
Designed layout and material replenishment for XT/LT Line
Designed in Quality at the source
Implemented one piece flow for assembly
2002New product cell
Implemented Managing for Daily Improvement Tools for Manufacturing
Developed metrics; engaged team leads and team members
Applied Lean principles to the development of new products from Voice
of Customer to Manufacturing to market release
2003 to 2004Managing for daily improvement
2008 to 20105S and Value Stream
2011 to 2013Kaizen and SS introduction
AfterBefore
Lean recognition2014 awards and accomplishments
Winners of the 2014 Roche Germany Innovation Award
Winners of the 2014 AME Manufacturing Excellence Awards
Vorne Board with OEE(Overall equipment effectiveness)
Lean Journey exampleDispenser Build and Test Process
Dispenser uses Automated & Manual Fill
Antibodies Detection Molecular
Prep Kits User fillable kits
Kits for BenchMark
Dispenser automation journey
Dispenser manual assembly
Manual build: Right to left with 2 operators1st Operator: Build dispenser & coupler2nd Operator: Assemble & test
Manual prime to semi-automated
Dispenser test methodsDrop measurement and pressure decay testing
Single Minute
Exchange of Dye(SMED)
Total Preventativ
e Maintenanc
e(TPM)
Just in Time(JIT)
Visual controls
Production
Planning Process
(3P)
Process monitori
ng
5s Kanban Standard work
Heijunka
Process smoothi
ngKaizen
Lean Enterprise
Jidoka
Introducing dispenser automation
DVM - Dispenser Verification Module
Scale: technical details• resolution: 0.1 mg/µl• accuracy: ± 0.5mg/µl• settling time: ~1s
DM Drop Measurement Specification
• 5 drops from each dispenser • 5 volume measurements• Average ≥ 88µl but ≤100µl• Standard deviation ≤ 2.00
3 dispensers tested at once 3 scales in parallel 3 scale related dripping cup
(150ml) 3 evacuating nozzles
Data concept / traceability/ Remote access concept
puck RFID+ cell-no
Dispenser ID puck RFID
Dispenser ID+ cell-no
Dispenser ID-PDT values+pass/fail result-drop values+pass/fail result-final result+deposited bin type
Case of change management
Employee involvement in the project
Ergonomically designed work stations
Improved workflow
Automated test station reducing physical stress
Drop in productivity
Fully automated reagent dispenser assembly concept
Barrel
Plug
Duckbill
Insert
Filter
Coupler
Balls
Ball Seat
Lower Seal
Quad SealStopSpring
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Fully automated reagent dispenser assembly concept
Summary
Building a Lean Enterprise is a Journey not the destination
Conceptual training needed at every stage with ongoing refresh is key to
success
Employee involvement and clear communication critical at every stage
Management must be receptive to the ideas generated on the floor – some of
the best ideas come from there
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Questions?
Employee engagement through Lean driven innovation
Himanshu Parikh, Ph.D.VP, Manufacturing Operations
Roche DiagnosticsVentana Medical Systems, Inc.
Thank You!Please complete the session survey at:www.ame.org/survey
Session: (i.e. TP/16 - # will be advised)Employee engagement through Lean Driven InnovationHimanshu ParikhRoche DiagnosticsVentana Medical Systems, Inc.himanshu.parikh@roche.com
Confidential and proprietary to Ventana Medical Systems, Inc. For internal use only. Do not copy. Do not distribute.
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