Company
Profile
Problem
Statement
Solution
by Innomaint
A world-class ophthalmic consumables manufacturer and exporter in the business for over four decades, is a proud customer of Innomaint. Its main products include intraocular lenses(IOL), surgical sutures, pharmaceutical products, surgical blades, etc. The manufacturer operates with a vision of making high-quality ophthalmic products affordable to all strata of society. The production house exports its products to 130+ countries at present. They follow strict quality measures in production as per US FDA, EU GMP, and WHO GMP norms. In 1998, the organization became the first IOL manufacturer in the country to secure ISO:9001 for process quality. The firm leverages its capabilities for manufacturing allied healthcare products such as cardiovascular sutures, microsurgical hand sutures, antiseptics, disinfectant solutions, etc. The unit shows a keen interest in adopting IoT to better its process.
| Industry | Ophthalmic consumables manufacturer |
| Established | 1992 |
| Location | India |
Problem Statement
The IOL manufacturing department reported breakdowns and submitted PPM requests that lined up. The unexpected breakdowns formed the bulk of the maintenance expenses and time. The company wished to manage its preventive and corrective maintenance with a maintenance management software.
- Identifying genuine spares which delayed prompt fixes. Managing inventories and knowing the closing spare stock at the end of each transaction.
- Assigning service requests to technicians in various shifts. Recording the problems to track them and take note of equipment downtime. Calculate the total downtime of factory assets.
- The workers faced difficulties raising service requests for machinery whose details were unknown. They wasted time in acquiring this information which was vital for fixes.
- Based on the practicability of the solution in the IOL department, they wished to implement it in all other departments, such as Pharmaceuticals, Utilities, etc.
- The Management wished to provide a means to record every problem statement and a digital acknowledgment of the fixes for continuous improvement of maintenance operations.
- The maintenance manager received breakdown intimations and service requests via mobile calls, verbal conversations, emails, etc., which were tedious for gathering, prioritizing, and tracking.
Solutions by InnoMaint
InnoMaint helped the concern in quicker setup and migration of entire asset data from Excel sheets to the EAM application in one go with easily traceable log information indicating the upload status.
InnoMaint provided the ability to randomly generate unique QR codes to print on every machine and spare readily for a unique identity. The application enabled them to pull out all machine details like manufacturer name, make, model, year of purchase, etc., in a single simple QR code scan using a mobile. Anyone from the manufacturing unit could raise a service or breakdown request instantly.
Besides this, the operators could raise a quick ticket by scanning the QR code using a Barcode scanner and auto assigning it to a technician. Technicians were grouped based on department, skills, and auto-assigned to tasks. In the case of auto-assignment, any member can rise to the occasion by accepting the assigned task disabling it for the rest. The technicians, in turn, gained rapid access to the maintenance pages of assets in the Innomaint EAM with a QR code scan. As this data was on the table, delivering sound and complete fixes was well within reach. With a mobile app for every technician on an Android Tablet, they can easily log their maintenance work.
The InnoMaint EAM software stores user information in a cloud environment retrievable anytime from anywhere. Supervisors distributed work evenly based on the full view of the current workload. This feature ensured no work was long overdue for the availability of a technician. Stakeholders were able to set preferences for in-app, mobile & email notifications.
The system offered an easy-to-use mobile app that the technicians could use to accept preventive and corrective work orders, access all the required information from one place, update their progress, and complete work orders from anywhere in the plant.
Results
✔ Technicians were quickly alerted to any issues needing attention.
✔ Complete elimination of paperwork for maintenance
✔ Spares were available instantly on the need for quicker completion of work orders
✔ Organization-wide visibility on the entire cycle of work orders
✔ Comparison of work orders in both excel and pdf format
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