Sponsored Content: Cerba ResearchReviewed by: Louis CastelSeptember 25, 2024
In this interview, NewsMedical speaks to Cerba’s Lukasz Wulnikowski about the power of automation and how it has dramatically changed the way they approach their kit building line.
What motivated you to automate the kit building process and how has it improved efficiency and accuracy?
We recognize the importance of thinking outside the box to drive our business forward and have found it extremely beneficial to take advantage of current technological advancements, while at the same time remaining committed to ensuring the highest quality of our products.
With the introduction of RFID tags, 100% accuracy was achieved, effectively eliminating human error. Moreover, efficiency was doubled by breaking down production into separate steps at each workstation. This streamlined process reduced complexity for the team, making task execution easier and smoother.
How has automation impacted your kit building operations? Can you provide some examples that demonstrate this impact?
Production planning has become much easier and more accurate, and by using advanced technology and reducing the number of assembly operations compared to the previous process, quality issues have been reduced, resulting in greater satisfaction for all team members.
The previous quality control process involved visually inspecting every component in a kit box, scanning labeled components with a manual barcode scanner, and entering information into an Excel file indicating whether the correct labels were scanned.
Kit boxes containing labeled RFID components are automatically scanned within 1-3 seconds of passing two antennas. If all components are present the kit is sealed, if not the kit is rejected, stopping the line and forcing the user to remove the bad kit.
Image credit: Gorodenkoff/Shutterstock.com
How does automation improve the quality standards of your kits and what challenges have you faced during implementation?
The quality of our kit products reaches an incredible level of 100% accuracy, consistency and precision. This achievement is made possible by integrating advanced software and a conveyor belt system with three workstations, each dedicated to a specific task. RFID labels and a monitoring station (troubleshooter) provide a comprehensive overview of the entire process, effectively eliminating human error.
Our processes are designed to stop production if a discrepancy is detected, requiring an operator to immediately intervene to remove and correct the faulty kit, ensuring that only compliant kits continue through the production line.
To meet quality standards and ensure compliance with GxP regulations, we have implemented a rigorous validation process. Due to the complexity of the system, we have established a dedicated team to meticulously document and record every instrument and each step of the process, ensuring full traceability.
Despite the numerous challenges and time-consuming nature of this project, the hard work and dedication of all involved ensured the successful completion and delivery of this highly efficient production line.
How do you handle technical issues with your automated equipment to ensure smooth operation?
We have scheduled daily and weekly check-ins, our team members are trained to clean and maintain each piece of equipment, and our SLAs (Service Level Agreements) with our vendors allow for extremely fast response times of 8 to 24 hours.
Are there any innovations or advancements you’re particularly excited to see in the future?
We plan to increase the number of kits on our automated lines and introduce pre-labeling to increase efficiency. Furthermore, we are also digitalizing our processes. One of the major projects currently underway is directly related to our kit lines and aims to give both us and our customers a comprehensive overview of all orders, kits, samples and storage. The system provides real-time visibility 24/7.
“At the same time, we are also exploring the idea of doubling the production capacity of our kit line through further improvements. With these advancements, we expect 2025 to be an exciting year full of opportunities for growth and innovation.”
Cerba Research – Kit Building – RijswijkPlay
Video credit: Cerba Research
How has automation changed your workforce? What training and development programs are in place to empower your workforce?
Employees reported that task division had improved and workflow was more organized and structured. Despite increased production capacity, employees do not feel the need to work harder or faster because the workload remains the same due to efficient process design.
To bring everyone on board with the new process, we created new roles and added some small tasks to our team responsibilities, so that all team members could plug into the updated workflow.
We have developed detailed work instructions covering both our processes and equipment. Each employee has received comprehensive theory and practice training on these documents, including hands-on training at each workstation. Additionally, we value all feedback we receive and use it to guide future process improvements.
How can automation help reduce waste and maximize resource utilization?
Going paperless is the way of the future and our upcoming dashboard will eliminate the need for physical documentation, as everything will be digitalized, automatically generating digitally managed files after each production run, eliminating the need for printing and signing.
We’ve also upgraded one of the labels on our kits to a sealed label that contains comprehensive information and a barcode. In many cases, the kit purchase orders will also be replaced with a digital version; however, due to the global distribution of our products, some kits will still require a paper purchase order.
What makes your automation process different from other organizations? How do you collaborate with your clients to create customized automation solutions?
We are the only company (to my knowledge) that offers automation of kit manufacturing and guarantees 100% quality of each kit. In this case, RFID labels are important because they are an innovative technology that is not commonly used.
We have entrepreneurial spirit in our DNA and we are already offering customized solutions we call “White Glove Logistics Services.”
Our line allows you to easily design your kits, labels and the information that will appear on the kit itself (or even a customized sealing label). Besides our kit line, we also offer many types of custom made boxes.
How do you stay on top of the latest automation trends and technologies to drive innovation in your role?
I am a strong advocate of continuous improvement and after implementing the line, my team and I have already identified further enhancements to optimize the line while maintaining the highest quality standards.
We’re also excited about the potential of future AI developments. The possibilities that AI can offer in both enhancing our kit line and streamlining our daily operations and inventory management are very promising. We live in an exciting time where innovation knows no bounds.
About the Speaker
Lukasz Wulnikowski is the Production and Supply Manager at Cerba Research Netherlands. His strong ability to take responsibility not only for his own tasks but also for the people he works with, and his analytical skills allow him to find structured and organized solutions and easily identify and address mistakes and areas for improvement.
About Cerba Research
For over 35 years, Cerba Research has set the industry standard for exemplary clinical trial conduct. Today, with operations spanning five continents and a focus on precision medicine, Cerba Research is changing the paradigm of the role of central laboratories in complex clinical research.
From protocol initiation to development to market launch, our passionate experts deliver the highest quality, specialized and personalized laboratory and diagnostic solutions. Partner with us to develop the most efficient strategies to bring your biotech and pharmaceutical products to fruition faster and improve the lives of patients around the world.