CARDIAC CATHETERS Cardiac catheters are used for both diagnostic and interventional purposes. During diagnostic procedures, catheters monitor blood flow and pressure within the heart, as well as provide a conduit to deliver radiopaque media that enables visualization of the vascular system. Integra Biotechnical, LLC 2731 Loker Ave West Carlsbad, CA 92010 Phone 760.931.1844 Fax 760.931.1753 www.integrabio.com Manufacturing Issue Product was manufactured in the US at a customer facility constrained for growth, and due to the high labor content was less competitive in the global marketplace. Program Results Produced over 300 SKUs, including small, custom production runs The Challenge Integra was tasked to carry out the following initiatives: • Take over manufacturing of legacy product line in order to free up capacity in existing customer facility • Provide a lower cost near-shore solution that would allow the customer to compete on a global scale and improve margins Integra’s Advantage Flexibility in manufacturing processes is essential when transferring projects with large numbers of SKUs and a combination of large and small production runs. The ability to be flexible in order to meet the customer’s needs is what sets Integra apart. Integra is uniquely positioned to provide unparalleled quality along with the economic benefits of near-shore manufacturing. This, coupled with dedication to continuous improvement through critical activities, such as value stream analysis and regular Kaizan events, made the overall manufacturing process more cost effective and allowed the customer to be more competitive. ©Copyright Providien, LLC. All rights reserved. Integra Biotechnical, LLC is a division of Providien, LLC www.providienmedical.com Increased production by 50% month-over-month during six month ramp-up Continuous improvement through value stream analysis and regular Kaizan events Integra’s Advantage Crucial Success Factors Flexibility in manufacturing processes is essential when transferring projects with large numbers of SKUs and a combination of large and small production runs. The ability to be flexible in order to meet the customer’s needs is what sets Integra apart. Integra is uniquely positioned to provide unparalleled quality along with the economic benefits of near-shore manufacturing. This, coupled with dedication to continuous improvement through critical activities, such as value stream analysis and regular Kaizan events, made the overall manufacturing process more cost effective and allowed the customer to be more competitive. Implementation Experience and technical expertise have enabled Integra to develop a systematic approach to successfully execute manufacturing transfers. Benchmarking current processes and capturing best practices, completing detailed equipment and process qualifications, as well as providing engineering support and training, insured a seamless transition to the new manufacturing line. Once the transfer was effectively completed, workflow optimization was achieved by converting all production lines from the original batch process to one-piece flow. This improvement resulted in program wide waste reduction and more efficient manufacturing processes across all SKUs. In addition to meeting the customer’s large daily scheduled production needs, Integra simultaneously produced highly specialized, low-volume custom products that are essential to the customer’s business model. Catheter Line Operations Integra produces a wide range of catheters utilizing the following operations: • • • • Tipping Hole Punching Skiving Hub Assembly • • • • Balloon Placement Tip curving Packaging Sterilization Management ©Copyright Providien, LLC. All rights reserved. Integra Biotechnical, LLC is a division of Providien, LLC www.providienmedical.com Ability to reduce manufacturing costs while also maintaining high quality standards Agility to take on extensive number of SKUs while also handling small custom runs Implementation of continuous improvement programs to reduce waste and provide cost savings
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