Related Case Studies
Industry: Medical
Technology: VLM, 24V Motorized Driven Roller Conveyor
Medical Supply Client
SITUATION
Johnson & Johnson, Inc. acquired the assets of the Synthes product line and desires to integrate the Synthes business into the existing DePuy operation at the J&J Distribution Center based in Markham, Ontario. Johnson & Johnson partnered with TriFactor Solutions to assist the Markham staff with analysis and design of the combined operating area.
The general scope of the TriFactor analysis and design work with Toronto Operations was to develop the process flow of materials from receiving through processing into storage, the order selection process, and to the packing operations. Specifically, this included the following functions:
- Integrate the Synthes loaner business (kit receiving, washing, control of inventory, reassembly of kits, repair) into the current DePuy operation
- Integrate the Synthes trauma business into the current DePuy operation
- Develop a plan to store the Synthes finished goods in the Toronto DC
ASSESSMENT
TriFactor Solutions visited both the current Synthes location and the Toronto DC. TriFactor took field measurements and verified the location of equipment in the current DePuy loaner processing area and updated the existing J&J drawings. TriFactor used this as a baseline drawing for the analysis. Additionally, TriFactor analyzed the SKU and movement data for DePuy loaner, Synthes loaner and Synthes finished good in order to determine the proper type and size of automated storage and retrieval or goods-to-person technology.
SOLUTION
After several iterations of concepts and layouts between all stakeholders, it was determined that the optimal solution included pallet lifts and zero pressure accumulation conveyor in the new in-bound kit processing area for both Synthes and DePuy. The combination of this equipment provided safety, good ergonomics and a sufficient queue of inbound kits prior to the washer area. Additionally, the optimal solution required Vertical Lift Module (VLM) technology for the storage needs, as well as for control and picking of elements of the loaner kits to support customer orders. VLM technology gave Johnson & Johnson high density storage that significantly reduced the floor space requirements for product storage which gave them the flexibility to expand other functions within the DePuy/Synthes operation.
RESULT
The project provided Johnson & Johnson with the ideal integration of the Synthes product line into the existing DePuy operations. The project was performed on time and under budget all the while allowing the operations to continue to function without sacrificing customer service.
ROI
1 – 2 Years
Customer:
- Johnson & Johnson, Inc.
TriFactor Provided:
- Needs Analysis
- Design Engineering
- Material Handling Equipment
- Mechanical & Electrical Installation
- Software & Integration
- Operator and Maintenance Training
Products Utilized:
- (6) Vertical Lift Modules
- Industrial Steel Shelving
- 24VDC MDR Zero Pressure Accumulation Conveyor
- Ergonomic Pallet Lifts
