Pharmaceutical manufacturing: the cold truth

CHRIS JOHNSON| March 26, 2019
PHARMACEUTICAL MANUFACTURING: THE COLD TRUTH
Low-temperature reactions are widely used in pharmaceutical manufacturing. Temperatures of approximately -80°C are sufficiently cold for most cGMP requirements, but as Chris Johnson, managing director of miniature bearing supplier SMB Bearings explains, these extreme temperatures create design challenges for machinery components.

Spotlight

McNeilus Truck and Manufacturing, Inc.

McNeilus Truck and Manufacturing Inc., an Oshkosh Corporation company, is an industry leading manufacturer of concrete mixers and refuse truck bodies. McNeilus has long been the industry standard when it comes to transporting concrete to the job site with our rear discharge Standard, Bridgemaster and SMS Sliding Mixers, as well as the Oshkosh S-Series front discharge mixer.

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What are the Risks that Manufacturing Face in the Current Times?

Article | December 30, 2021

Risk management in manufacturing has always been a top priority for manufacturers to avoid any unfortunate incidents. As a result, it is possible to create a more secure work environment for employees by conducting risk assessments and implementing remedies. “If you don’t invest in risk management, it doesn’t matter what business you’re in, it’s a risky business.” – Gary Cohn, an American Business Leader. As of 2019, the worldwide risk management market was valued at $7.39 billion, and it is expected to rise at a CAGR of 18.7% from 2020 to 2027, according to allied market research. Why is Risk Assessment Critical in Manufacturing? The manufacturing industry must have a credible risk assessment and management plan to defend itself from any breaches. Risk assessment helps firms understand the dangers they face and their implications if their systems are compromised. Hence, risk assessment is very critical in the manufacturing industry. Five Risk Assessment Principles Identify hazards/risks - Employers must examine their workers' health and safety risks. Therefore, an organization must regularly inspect its employee’s physical, mental, chemical, and biological threats. Identify who may be hurt and in what way – Identifying the personnel both full-time and part-time at-risk. Employers must also examine threats to agency and contract personnel, visitors, clients, and other visitors. Assess the risks and act accordingly - Employers must assess the likelihood of each danger causing injury. This will evaluate and lower the chance at the working space. Even with all safeguards, there is always some danger. Therefore, employers must assess if danger is still high, medium, or low risk. Get the Risks Documented - Employers with five or more employees must record the critical findings of the risk assessment in writing. In addition, register any risks identified in the risk assessment and actions to minimize or eliminate risk. This document confirms the evaluation and is used to examine working practices afterward. The risk assessment is a draft. It should be readable. It shouldn't be hidden away. The risk assessment must account for changes in working techniques, new machinery, or higher work objectives. 5 Manufacturing Risks to Consider in 2022 Accidents at Work Even if official safety policies and programs are designed, followed, and enhanced, manufacturers may endure workplace accidents and injuries. Risk assessment for workplace accidents assists in mitigating the negative impact on both employees and the organization. Environmental Mishaps Manufacturers have distinct issues regarding fuel handling and hazardous waste disposal in facilities. Sudden leaks or spills may be extremely costly to clean up and result in fines from state and federal agencies. Risk assessments for such plant accidents assist businesses in mitigating financial losses. Equipment Breakdowns Essential machinery throughout the production process might fail at any time, incurring significant repair or replacement costs. Therefore, it's critical to recognize that business property insurance may not cover mechanical issues. Risk assessment and prepayment solutions protect against equipment failures without interfering with typical company operations. Supply Chain Disruption Dependence on your supply chain may result in unintended consequences that are beyond your control. For example, if you experience downtime on the manufacturing line due to a supplier's failure to supply materials or parts, you risk losing revenue and profitability. If a disturbance to your supply chain poses a hazard, risk management can assist you in managing it more effectively by quickly identifying the risk and providing a suitable response. Operation Temporarily Suspended Depending on the severity of the weather event, a factory might be severely damaged or perhaps utterly wrecked. While major repairs or rebuilding are being undertaken, recouping lost income might be vital to the business's future profitability. Risk assessment in this area enables your organization to budget for overhead expenditures such as rent, payroll, and tax responsibilities during the period of suspension of operations. Final Words Risk management is critical in manufacturing because it enables manufacturers to comprehend and anticipate scenarios and create a well-planned response that avoids unnecessary overhead costs or delays in delivering the production cycle's final result. Manufacturing risks are undoubtedly not limited to the risks listed above and may vary according to the nature of the business and regional environmental conditions. Therefore, create a well-defined strategy to overcome threats in your business and be productive at all times. FAQ How are manufacturing business risks classified? In most cases, the business risk may be categorized into four types: strategic risk, regulatory compliance risks, operational compliance risks, and reputational risks. Why should a manufacturer conduct a risk assessment? Every manufacturing employment has risks for injury or illness. But risk evaluations can significantly minimize workplace injuries and illnesses. In addition, they assist companies in discovering strategies to reduce health and safety risks and enhance knowledge about dangers.

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Top 5 Manufacturing Applications of Machine Vision

Article | October 20, 2021

Machine vision is becoming increasingly prevalent in manufacturing daily across industries. The machine vision manufacturing practice provides image-based automated inspection and analysis for various applications, including automatic inspection, process control, and robot guiding, often found in the manufacturing business. This breakthrough in manufacturing technology enables producers to be more innovative and productive to meet customer expectations and deliver the best products on the market. A renowned industry leader Mr. Matt Mongonce conveyed in an interview with Media7, As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity -Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca. Why is Machine Vision so Critical? The machine vision manufacturing process is entirely automated, with no human intervention on the shop floor. Thus, in a manufacturing process, machine vision adds significant safety and operational benefits. Additionally, it eliminates human contamination in production operations where cleanliness is critical. For instance, the healthcare business cannot afford human contamination in some circumstances to ensure the safety of medicines. Second, the chemical business is prohibited from allowing individuals to come into touch with chemicals for the sake of worker safety. Thus, machine vision is vital in these instances, so it is critical to integrate machine vision systems into your production process. Machine Vision Application Examples To better understand how businesses are utilizing machine vision in production, we will look at five cases. Predictive Upkeep Even a few seconds of production line downtime might result in a significant financial loss in the manufacturing industry. Machine vision systems are used in industrial processes to assist manufacturers in predicting flaws or problems in the production line before the system failure. This machine vision capability enables manufacturing processes to avoid breakdowns or failures in the middle of the manufacturing process. How is FANUC America Corporation Avoiding the Production Line Downtime with ROBOGUIDE and ZDT? FANUC is a United States-based firm that is a market leader in robotics and ROBOMACHINE technology, with over 25 million units deployed worldwide. In addition, the company's professionals have created two products that are pretty popular in the manufacturing industry: ROBOGUIDE and ZDT (Zero Down Time). These two standout products assist manufacturers in developing, monitoring, and managing production line automation. As a result, producers can enhance production, improve quality, and maximize profitability while remaining competitive. Inspection of Packages To ensure the greatest possible quality of products for their target consumer groups, manufacturers must have a method in place that enables them to inspect each corner of their product. Machine vision improves the manufacturing process and inspects each product in detail using an automated procedure. This technology has been used in many industries, including healthcare, automation, and electronics. Manufacturers can detect faults, cracks, or any other defect in the product that is not visible to the naked eye using machine vision systems. The machine vision system detects these faults in the products and transmits the information to the computer, notifying the appropriate person during the manufacturing process. Assembly of Products and Components The application of machine vision to industrial processes involves component assembly to create a complete product from a collection of small components. Automation, electronics manufacturing, healthcare (medicine and medical equipment manufacturing), and others are the industries that utilize the machine vision system in their manufacturing process. Additionally, the machine vision system aids worker safety during the manufacturing process by enhancing existing safety procedures. Defect Elimination Manufacturers are constantly endeavoring to release products that are devoid of flaws or difficulties. However, manually verifying each product is no longer practicable for anybody involved in the manufacturing process, as production counts have risen dramatically in every manufacturing organization. This is where machine vision systems come into play, performing accurate quality inspections and assisting producers in delivering defect-free items to their target clients. Barcode Scanning Earlier in the PCB penalization process, where numerous identical PCBs were made on a single panel, barcodes were used to separate or identify the PCBs manually by humans. This was a time-consuming and error-prone process for the electronics manufacturing industry. This task is subsequently taken over by a machine vision system, in which each circuit is segregated and uniquely identified using a robotics machine or a machine vision system. The high-tech machine vision system "Panel Scan" is one example of a machine vision system that simplifies the PCB tracing procedure. Final Words The use of machine vision in the manufacturing business enables firms to develop more accurate and complete manufacturing processes capable of producing flawless products. Incorporating machine vision into manufacturing becomes a component of advanced manufacturing, which is projected to be the future of manufacturing in 2022. Maintain current production trends and increase your business revenue by offering the highest-quality items using a machine vision system. FAQ What is the difference between computer vision and machine vision? Traditionally, computer vision has been used to automate image processing, but machine vision is applied to real-world interfaces such as a factory line. Where does machine vision come into play? Machine vision is critical in the quality control of any product or manufacturing process. It detects flaws, cracks, or any blemishes in a physical product. Additionally, it can verify the precision and accuracy of any component or part throughout product assembly. What are the fundamental components of a machine vision system? A machine vision system's primary components are lighting, a lens, an image sensor, vision processing, and communications. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is the difference between computer vision and machine vision?", "acceptedAnswer": { "@type": "Answer", "text": "Traditionally, computer vision has been used to automate image processing, but machine vision is applied to real-world interfaces such as a factory line." } },{ "@type": "Question", "name": "Where does machine vision come into play?", "acceptedAnswer": { "@type": "Answer", "text": "Machine vision is critical in the quality control of any product or manufacturing process. It detects flaws, cracks, or any blemishes in a physical product. 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Three Business Examples That Effectively Practice Lean Manufacturing

Article | December 13, 2021

Lean manufacturing principles enable manufacturing businesses to achieve spectacular results and overhaul their conventional operations. A wide range of industries have adopted lean manufacturing because of its enormous advantages, and they have seen excellent results as a result. The 2010 Compensation Data Manufacturing survey indicated that 69.7% of manufacturing organizations employ lean manufacturing principles. By consuming this data, we can understand how far organizations have progressed toward incorporating lean principles into their operations. “Many companies are not willing to change or think they are done once they make a change. But the truth is technology, consumer demands; the way we work, human needs, and much more are constantly changing.” –Michael Walton, Director, Manufacturing Industry Executive at Microsoft Let's look at some examples of lean manufacturing from some well-known companies. These leading-edge examples of lean manufacturing will shed light on how lean principles positively affect. Leading Companies Using Lean Manufacturing Effectively Successful manufacturing businesses like Toyota, Nike, and Caterpillar are currently employing lean manufacturing ideas in their production processes. In addition, Intel, Parker Hannifin, and John Deere embrace these techniques. From them, we've described three different organizations in various sectors that are successfully adopting lean manufacturing. JOHN DEERE John Deere has also implemented a lean manufacturing strategy. As a result, many of their quality control procedures are automated, which means that more components can be checked for flaws in less time. This means that more supply can be released each day, and the product can be supplied at a lower price to the consumer. Additionally, these controls monitor the manufacturing process for each component of their products, ensuring that they never manufacture more than is required and waste essential materials in the process. INTEL Intel, known for its computer processors, has used lean manufacturing techniques to provide a higher quality product for an industry that requires zero defects. In the past, it took more than three months to get a microprocessor to the manufacturer, but this principle has helped shorten that time to less than ten days. Intel rapidly learned that creating more but worse quality was not the way to raise revenues and increase consumer satisfaction with its products, which were extremely precise and technical. Instead, both parties gain from quality control and waste reduction initiatives. This is even true in the tech industry, where goods are constantly changed and upgraded. TOYOTA Toyota, the world's largest automaker, was the first to implement lean manufacturing in its manufacturing operations. But, even more importantly, they've learned how to limit products that don't match customer expectations by eliminating waste. To achieve these goals, Toyota employs two essential procedures. The first is a method known as Jidoka, which loosely translates as "automation with the assistance of humans." This implies that, although some of the work is automated, humans always ensure that the result is of the highest quality. When something goes wrong, the machines have built-in programs that allow them to shut themselves down. Known as the Just In Time (JIT) model, this is the second stage. Once the last part of a process has been finished, the next phase can begin. No unnecessary work will be done if there is a problem with the assembly line. This lean manufacturing technique has inspired thousands of other businesses. Final Words Lean manufacturing principles and their execution require discipline and patience to get the results out of them. When we see the successful lean manufacturing examples, it is not a fraction of a second success. They have devoted their time, energy, and efforts to modifying every single operational process in order to become a part of lean manufacturing. Lean manufacturing is not a method; it is a way of life that transforms your business practices and takes your firm to a new level of operations. Gain insights from renowned organizations' lean manufacturing success stories to help you become a part of the lean companies of 2022. FAQ What is the effect of lean manufacturing? Lean is a performance-based, continuous-improvement strategy that removes waste and unnecessary processes from organizational operations. As a result, your company becomes more focused on the results. Is it possible for lean manufacturing to fail? It is conceivable in some circumstances, such as failing to focus on a single system implementation or implementing too many system changes at once and failing to have a sound follow-up system to check that everything is working effectively. Why do certain businesses struggle with lean manufacturing? Most businesses fail to see that lean is a management philosophy, not a set of tools. As a result, most corporate leaders either don't understand or lack the patience and control to implement lean manufacturing. { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [{ "@type": "Question", "name": "What is the effect of lean manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Lean is a performance-based, continuous-improvement strategy that removes waste and unnecessary processes from organizational operations. As a result, your company becomes more focused on the results." } },{ "@type": "Question", "name": "Is it possible for lean manufacturing to fail?", "acceptedAnswer": { "@type": "Answer", "text": "It is conceivable in some circumstances, such as failing to focus on a single system implementation or implementing too many system changes at once and failing to have a sound follow-up system to check that everything is working effectively." } },{ "@type": "Question", "name": "Why do certain businesses struggle with lean manufacturing?", "acceptedAnswer": { "@type": "Answer", "text": "Most businesses fail to see that lean is a management philosophy, not a set of tools. As a result, most corporate leaders either don't understand or lack the patience and control to implement lean manufacturing." } }] }

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Microfinancing in Uganda Works with Lean Manufacturing Precision

Article | November 23, 2021

Having recently returned from Uganda, had the pleasure of being introduced by Bernard Munyanziza of Nziza Hospitality to Gilbert Atuhire. He is the Managing Director at Value Addition Microfinance Ltd. which provides micro loans to producers and manufacturers. Atuhire is an attorney by training, however his ability to articulate the core values of Lean Six Sigma and continuous process improvement were abundantly clear. The Kampala, Uganda offices are located on Parliamentary Avenue and Dewinton Rise. This central location allows direct access to industrial projects.

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Spotlight

McNeilus Truck and Manufacturing, Inc.

McNeilus Truck and Manufacturing Inc., an Oshkosh Corporation company, is an industry leading manufacturer of concrete mixers and refuse truck bodies. McNeilus has long been the industry standard when it comes to transporting concrete to the job site with our rear discharge Standard, Bridgemaster and SMS Sliding Mixers, as well as the Oshkosh S-Series front discharge mixer.

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