maximo at ortho-clinical diagnostics - ibm
TRANSCRIPT
© Ortho-Clinical Diagnostics, Inc.
Maximo at Ortho-Clinical Diagnostics
Cynthia Day
Operations Engineering
Engineering Systems
November 2014
2 © Ortho-Clinical Diagnostics, Inc.
Who – Introduction to OCD
Why – Why Maximo
When
What & How
–Equipment
– Introduction of Maximo
– Introduction of Calibration
– Introduction of enterprise CMMS
Conclusion
Agenda
3 © Ortho-Clinical Diagnostics, Inc.
Who - Introduction to OCD
4 © Ortho-Clinical Diagnostics, Inc.
2010
1997
1985
1989
1990
1993
1995
Amersham launches Amerlite Diagnostic
System with enhanced chemiluminescence
Launch of first HCV test
Eastman Kodak & Amersham
International joint venture
Kodak Clinical Diagnostics formed
J&J acquires Kodak Clinical, merges with Ortho Diagnostic
Systems & forms Ortho Clinical Diagnostics (OCD)
OCD launches VITROS ECi System
2004 OCD Launches ECiQ Immunodiagnostic System
2009
2012 Menu >50 assays
HIV, PSA, Syphilis
Manufacturing moves to new site in
Pencoed, South Wales
OCD Launches VITROS 3600 and 5600 Integrated Systems
2014 OCD becomes
stand alone
company
OCD Pencoed History
5 © Ortho-Clinical Diagnostics, Inc.
Products that save
lives
Professionals
dedicated to product
quality
Excellence through
technology
Purpose P PENCOED P
Supply >150 million test per
year to around the world
Provide high accuracy test
results that allow diagnosis of
diseases including hepatitis,
HIV, cancers and metabolic
diseases
Have quality central to our
thinking
6 © Ortho-Clinical Diagnostics, Inc.
OCD Key Facilities
Rochester, NY Research & Development
Equipment Mfg
Clinical Chemistry Slide Mfg Fluids / Micro tip Mfg
Raritan, NJ Worldwide HQ
Donor Screening Mfg
Immunohematology Mfg
Memphis, TN US Distribution Centre
Pencoed, Wales Immunoassay Mfg
Strasbourg, France
Worldwide Distribution Centre
7 © Ortho-Clinical Diagnostics, Inc.
Reproductive & Pregnancy
Kidney/Adrenal gland Cortisol
Digestive & Pancreas CA 19-9
CEA –
carcinoembryonic antigen
Thyroid & Parathyroid
Free or Total T3 and T4
Hormones TSH – Thyroid Stimulating
Hormone
T3U – T3-Hormone
Uptake iPTH – intact Parathyroid Hormone
Liver & Hepatitis A,B & C
HAV – Hepatitis A Virus
(HAV IgM, aHAV Total)
HBs/eAg – Hepatitis B
Antigen (HBsAg, HBsAg ES, HBeAg)
aHB – anti-Hepatitis B
Antibodies (aHBs, aHBc, aHBe)
aHCV – anti-
Hepatitis C Virus
AFP – Alpha
fetoprotein
HORMONES
Estradiol LH – Luteinising
Hormone
FSH – Follicle
Stimulating Hormone
Prolactin Progesterone b-hCG – Beta
Human Chorionic Gonadotrophin
Testosterone
DISEASE
Pregnancy - Screening For ToRC Diseases
Toxo – Toxoplasma gondii
Rub – Rubella
CMV – Cytomegallovirus
Toxo IgG, Toxo IgM Rub IgG, Rub IgM CMV IgG, CMV IgM
CANCER
CA 125 II
CA 15-3
AFP – Alpha
fetoprotein
PSA – Prostate
specific antigen (tPSA, fPSA)
HIV & Syphilis
HIV Combo
aHIV – anti Human
Immunodeficiency Virus
Syphilis
Blood & Bones Vitamins, Iron & Skeleton
Ferritin
B12
Folate (B9)
Vitamin D NTx
Cardiac
CK MB –
Creatine Kinase Troponin I ES
(Extra Sensitive)
Myoglobin
NTproBNP – N-terminus pro-
Brain Naturetic Peptide
Menu of Assays Product P PENCOED P
8 © Ortho-Clinical Diagnostics, Inc.
Enhanced Chemiluminescent Immunoassay
Kits, Calibrators, Range Verifiers, Signal Reagent,
Controls
Complex Biological Raw Materials / Processes
Range of Analyser Platforms (made in OCD Rochester)
Product P PENCOED P
9 © Ortho-Clinical Diagnostics, Inc.
How It Works Signal Reagent (Luminol + stabilisers)
Troponin I
Biotinylated Anti-Troponin I Antibody
HRP-Conjugated Antibody
Streptavidin Coated Well
Sample
Streptavidin Coated Well
Biotinylated Antibody
Sample, e.g. Troponin I
HRP-Conjugated Antibody
Product P PENCOED P
Sandwich Assay
10 © Ortho-Clinical Diagnostics, Inc.
Raw
Materials
Calibrators
Reagents
QC & Release
Formulation
Coated Wells
Conjugates
>850 Primary
Raw Materials
>80 conjugate
reaction types
Kit Assembly
>200 SKUs
>60 kit
combination
tests
15 microwell
coating types >200 formulation
types
>100 types
of reagent
>150 types of cals,
>50 types of
controls/RVs
Process Overview P PENCOED P
11 © Ortho-Clinical Diagnostics, Inc.
Why - Maximo
12 © Ortho-Clinical Diagnostics, Inc.
Reasons to implement Maximo
• Consolidation
• Maintenance planning
• Standard and consistent practice
• Record maintenance
• Data retrieval and analysis
• Change control
• Quality, Regulatory and Compliance
• Business benefits
13 © Ortho-Clinical Diagnostics, Inc.
When - Maximo
14 © Ortho-Clinical Diagnostics, Inc.
Maximo Journey
Paper based
System
Nov 2007
Maximo 5.2 Maintenance
Jan and July 2008
Maximo 5.2 Second site: Pencoed
Maximo Calibration
Nov 2013
Maximo 7.5
J&J eCMMS
Third site: Facilities
Maximo 7.5 Options following
divestiture
15 © Ortho-Clinical Diagnostics, Inc.
What & How Maximo
16 © Ortho-Clinical Diagnostics, Inc.
OCD Pencoed Equipment
Automated Packaging Line
• Assembly and labelling of components (RPAM)
• Foil bagging and labelling of components
• Cartoning of foil bag (FPA)
• Adding of package inserts
• Labelling of carton
• Case packaging of cartons and labelling
17 © Ortho-Clinical Diagnostics, Inc.
Maximo – Maintenance Only
18 © Ortho-Clinical Diagnostics, Inc.
How Maximo is Used
Asset Management and Scheduling of Calibration
Preventative and Reactive Maintenance
Standard work processes
Movement of assets
Reporting
– Work Orders
– Look ahead
– Compliance
0
10
20
30
40
50
60
70
80
90
100
2011 2012 H1 2012 H2 2013 H1 2013 H2 2014 H1
Sc
he
du
le A
dh
ere
nc
e (
%)
Maintenance Period
Schedule Adherence Historic Trending
Calibration
Calibration Off Site
Preventative Maintenance
Service Contract
19 © Ortho-Clinical Diagnostics, Inc.
Maximo Calibration
20 © Ortho-Clinical Diagnostics, Inc.
Maximo Calibration
Related data can be accessed and also stored
securely
Transcription errors reduced
Paperless
Works Order approved with electronic signatures
Prompt response with Non-Conformance and
Corrective Action Preventive Action for calibration
failures
Related functionality and benefits with maintenance
21 © Ortho-Clinical Diagnostics, Inc.
Calibration Implementation
OCD Engineering Project Managed
Exponential learning on software for Operations
Engineering & Information Management
Design based upon experience and quality requirements
Minimal customisation
Qualification protocols written and executed
Introduced for new Pencoed site only
Training Modules written and service provider training
completed
22 © Ortho-Clinical Diagnostics, Inc.
Calibration Specification Justification
23 © Ortho-Clinical Diagnostics, Inc.
Maximo Calibration Module
24 © Ortho-Clinical Diagnostics, Inc.
ME2 Progress
25 © Ortho-Clinical Diagnostics, Inc.
Enterprise CMMS
26 © Ortho-Clinical Diagnostics, Inc.
Why eCMMS Maximo 7.5
J&J eCMMS
Introduction of a standard platform for 3 sectors of
J&J: MD&D, Pharma and Consumer.
37 sites in Phase 1 migrating from several different
systems.
The strategic target end state for CMMS was to go
to 1 single common IT platform.
Benchmark sites and ability to measure
performance.
27 © Ortho-Clinical Diagnostics, Inc.
The Challenge
Site X
Knowns: - Using a CMMS system to
manage maintenance processes - CMMS system rules defined by
local Site practices -System configuration -Reports/Reporting -System functions -Usability - Abiding by established local
procedures and Quality program
Enterprise Platform
Driving Standards: - Best Practice foundation - Business processes -Maintenance -Calibration -Spare parts/inventory - Centralized CMMS -System configuration -Reporting/Reports -System function/capabilities - Quality/compliance
28 © Ortho-Clinical Diagnostics, Inc.
Site Readiness Considerations
Business Process Readiness
– Adaptation to new standards for business processes designed within CMMS platform (e.g. work types, work priorities, roles, nomenclatures, workflow, reports, etc...)
Maximo 7.5 CMMS Readiness
– New technical platform
– New functionality/capability
– New reporting capabilities
Quality/Compliance Readiness
– Documentation (SOPs, Work Instructions, etc...)
– Local Site procedures consideration
Training
– Business processes
– Maximo 7.5 (System)
Reporting/Reports & Value
29 © Ortho-Clinical Diagnostics, Inc.
Conclusion
30 © Ortho-Clinical Diagnostics, Inc.
Conclusion
• Quality and Compliance.
• Electronic – remove need for paper.
• Standardisation (site & globally).
• Data analysis for productivity improvements.
• Efficient scheduling, reduce downtime and increase capacity.
• Automatic verdict of Calibration.
• Improved tracking and reporting.
• Centralised system management.
• Steep learning curve for Maximo calibration.
• Service providers’ reference devices or solutions.
• Sites at different levels of maturity.
• Turnaround for changes and improvements.
• Issues with reporting.
• Too much and not enough application access!
• Enterprise vision can conflict with Site practicalities.
• Migration of data for non Maximo software.
• Latency - Slow at times for calibration.
31 © Ortho-Clinical Diagnostics, Inc.
Next Steps and Summary
Next Steps
Johnson and Johnson divestiture
– 2 Ortho Clinical Sites share the MD&D and Consumer platform – UK and USA
– 1 Ortho-Clinical Diagnostic site shares the Pharma platform – USA
Facilities department
Continuous Improvement
Inventory
Summary
Maximo and Maximo Calibration has provided a platform that link OCD’s
robust processes and continuous improvement values that promotes
‘Excellence through Technology’ in asset management.