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Employee engagement through Lean driven innovation
Himanshu Parikh, Ph.D. VP, Manufacturing Operations
Roche Diagnostics
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 the mission to improve 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 • 656 granted patents worldwide and 520 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 In Patient Out
Tele-Pathology
Advanced Image Analysis
Pathologists Review
Case Assembly
AP Labs operate an integrated workflow
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 In Patient Out
Tele-Pathology
Advanced Image Analysis
Pathologists Review
Case Assembly
AP Labs operate an integrated workflow Digital Slide
Scanning & Analysis
Ventana solutions in the AP lab today
H&E
Ventana solutions
Primary Staining StingingH
E 600
BenchMark
Digital Slide Scanning &
Advanced Image Analysis
iScan HT
BenchMark
Sample Collection
Vantage
The Ventana Portfolio Delivering testing efficiency and medical value
Pre-analytical tissue preparation
Primary staining H&E stain
Advanced staining SS, IHC, ISH
Workflow management connectivity
Customer care and consultative services
Imaging/reporting image analysis
Single Minute Exchange
of Dye (SMED)
Total Preventative Maintenance
(TPM)
Jidoka
Just in Time (JIT)
Visual controls
Production Planning Process
(3P)
Process monitoring
5s Kanban Standard work
Heijunka Process smoothing Kaizen
Lean Enterprise
The Ventana Journey Began 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 teams o 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
2002 New 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 2004 Managing for daily improvement
2008 to 2010 5S and Value Stream
2011 to 2013 Kaizen and SS introduction
After Before
Lean Recognition 2014 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 Example Dispenser 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 operators 1st Operator: Build dispenser & coupler 2nd Operator: Assemble & test
Manual prime to semi-automated
Dispenser Test Methods Drop measurement and pressure decay testing
Single Minute Exchange
of Dye (SMED)
Total Preventative Maintenance
(TPM)
Just in Time (JIT)
Visual controls
Production Planning Process
(3P)
Process monitoring
5s Kanban Standard work
Heijunka Process smoothing Kaizen
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
Leadership Challenges
Change Management Employees Key stakeholders Regulatory compliance
Employee Engagement Employee involvement in the project Ergonomically designed work stations Improved work flow Automated test station reducing physical stress
25
Did the project get delivered?
26
Employee Engagement Activities • Aligned on management and employee expectation of output • Created team goal versus individual for daily output • Break for 10 minutes every hour to stretch • Safety and ergonomics assessments by external experts • Effective workflow management to reduce overtime
27
What’s Next?
“What is coming is better than
what will be gone” - Arabic proverb
28
Fully automated reagent dispenser assembly concept
Barrel
Plug
Duckbill
Insert
Filter
Coupler
Balls
Ball Seat
Lower Seal
Quad Seal Stop Spring
29
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
32
Questions?
Employee engagement through Lean driven innovation
Himanshu Parikh, Ph.D. VP, Manufacturing Operations
Roche Diagnostics
Confidential and proprietary to Ventana Medical Systems, Inc. For internal use only. Do not copy. Do not distribute.
Doing now what patients need next
6048A 0915
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 Innovation Himanshu Parikh Roche Diagnostics Ventana Medical Systems, Inc. [email protected]
