Background
EMD Millipore is a Life Science leader providing cutting-edge technologies, tools, and services for bioscience research and biopharmaceutical manufacturing. As a strategic partner, EMD Millipore collaborates with customers to confront the world’s challenging human health issues. From research through development to production, EMD Millipore’s scientific expertise and innovative solutions help customers tackle their most complex problems and achieve their goals.
The challenge
EMD Millipore had been relying on post-production testing to control quality in pleated cartridge assembly. Under the previous system, the cartridges were bonded and then placed on carts. The carts would then be moved to a testing room where post-production quality inspection would occur. If they passed the inspection, the cartridges would be placed back on the carts and moved to a drying area where they would dry before they could be packaged.
This approach was costing EMD Millipore a great deal of time. They were looking for a way to perform the quality tests during production so the cartridges wouldn’t need to be removed from the line. In-process testing would prevent quality issues from occurring, and would reduce the number of defects found during post-production. An ideal system would demonstrate that the bonded parameters were in statistical control and specification in a highly automated production environment—so the post-production testing and the associated handling could be eliminated.
The solution
EMD Millipore chose to implement InfinityQS® ProFicient™ after an on-site demonstration of the industry-leading SPC software. The automated tools and the powerful SPC charting capabilities stood out as key differentiators in the decision-making process. After the demonstration, EMD Millipore knew it could gain an immediate ROI on the software.
The results
InfinityQS’ real-time system enabled EMD Millipore to test cartridge bonding attributes during production and include the lot report as part of the batch record. InfinityQS’ real-time data analysis provided intelligence that allowed for the elimination of the post-production quality test in cartridge assembly. In cartridge assembly, EMD Millipore is achieving savings from the elimination of the test and reductions in scrap, rework, labor, and production overhead that total over $250,000 annually.
Along with the quality improvements, EMD Millipore was also able to leverage InfinityQS’ “lights out” tools to streamline their highly automated work cells, where operators are not always present while processes run. It is critical that operators, present or not, take action when a process begins to drift out of statistical control. InfinityQS’ Remote Event Monitoring Service (REMS) monitors EMD Millipore’s automated processes and shuts down the process if an out-of-control condition occurs.
Fast Facts:
- EMD Millipore is saving $250,000 annually using InfinityQS
- EMD Millipore has achieved savings by eliminating a quality test and reducing scrap, reworking, labor, and production overhead