Digitalized Compliance for Medical Devices

About the Customer

The customer is a leading global medical device manufacturer that designs, develops and produces products for different medical fields including cardiology, interventional radiology, orthopedics, electrophysiology and surgical management. The manufacturer was named among the top 100 medical device companies in 2018. They are also the sixth largest multinational producer of orthopedic products, including knee and hip replacement solutions.

Customer
Medical Device Manufacturer
Location
United States
Industry
Medical Device Manufacturing
Siemens Opcenter Execution Medical Device and Diagnostics

Challenge

The medical device manufacturer needed to replace a 25-year legacy MES and eliminate manual, paper-based FDA documentation that consumed significant time and resources, while improving synchronization and transparency between enterprise systems and the shop floor.

Solution

IndX designed and implemented a modern MES enabling electronic Device History Records using Siemens Opcenter Execution Medical Device and Diagnostics, delivered a new DNC solution with Shop Floor Connect, and fully integrated MES with DNC, PLM and ERP to create a single digital source of truth and support a paperless production environment.

Project Activities 

  • Conducted an in-depth requirements analysis to identify operational and compliance priorities
    • Recommended electronic Device History Record (eDHR) management as the optimal path to improve efficiency and maintain regulatory control
    • Designed an end-to-end MES solution to replace the legacy manufacturing system
    • Developed and configured Siemens Opcenter Execution Medical Device and Diagnostics to enable eDHR and digital Work-In-Progress tracking
    • Built a new Direct Numerical Control (DNC) system using Shop Floor Connect for Siemens Teamcenter
    • Integrated the MES with the DNC system to centralize shop floor production data
    • Connected the MES to the existing ERP system to exchange work orders and production performance data
    • Led the validation phase to support quality, compliance and system readiness
    • Implemented the new MES and DNC solutions at the flagship U.S. plant
    • Delivered end user training and ongoing system support to drive adoption and sustainability

    Business Drivers 

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    Replace legacy Manufacturing Execution System (MES)
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    Manufacturing system synchronization
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    Connect business level to shop floor – improve transparency
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    Move towards a paperless shop floor
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    Create a single source of truth via one digital system that acts as the central repository for all manufacturing data, and make this data easily available to operators on the shop floor
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    About the Project

    First, our team of medical device industry specialists led an in-depth analysis of the customer's requirements to better understand their most pressing challenges and recommend the right solutions to address them. The analysis identified electronic Device History Record (eDHR) Management as the best and most cost-effective solution to improve process efficiency while ensuring quality control and regulatory compliance at the same time.

    In order to enable eDHR and digitalize Work-In-Progress (WIP) on the shop floor, our IndX team then designed, developed and customized an end-to-end MES solution to replace the customer's existing legacy system, as well as a new Direct Numerical Control (DNC) system to provide the link between engineering, manufacturing planning and the machines on the shop floor. Our scope of work for this enterprise MES initiative included:

    • Designing and developing a new MES leveraging Siemens Opcenter Execution Medical Device and Diagnostics (previously Camstar) software
    • Designed and developed new DNC system leveraging Shop Floor Connect (SFC) for Siemens Teamcenter software
    • Integrating MES to DNC system to centralize management of all production data
    • Integrating MES to existing ERP system to enable sharing of work order and production performance data
    • Leading the validation phase, implementing the 2 new systems and providing end user and system support

    IndX's Advantage

    So, what is the real, measurable value gained by companies going paperless in the Medical Device Manufacturing environment? This customer is just one of many manufacturers in this sector with whom we are working on similar projects. Simply put, the use of paper to meet the stringent data collection and quality compliance requirements in this industry leads to a significant waste of time and resources whose skills could be better utilized in more value-add tasks. By going paperless, not only did our customer ensure consistent quality compliance, improve efficiency and streamline processes, but they will now be able to reallocate more of their resources and personnel to more complex and value-driving activities within their enterprise.

    Brandon Johnson

    Director of Services – MES/MOM Pillar
    Brandon is a business leader with 15+ years of experience building and leading IT consulting and system integration teams focused on Industry 4.0 and enterprise digital transformation in manufacturing. He has directly led $10M+ transformation programs and managed teams across large-scale IT application rollouts in pharmaceutical, medical device, food & beverage, and agroscience environments.
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