Services Provided
Manufacturing, operations, supply chain, global manufacturing; recruitment assistance
Med Area
Life Sciences; IVD manufacturing
Client Need
After receiving large NIH/DoD grants, a Board Member of Orasure Technologies (OTI), a publicly traded Life Science IVD manufacturing company, reached out to BCS for help in scaling their manufacturing. The Orasure BOD wanted BCS to perform an assessment of OTI’s current operations and what was required for them to meet their obligations to the government.
The scope included: manufacturing at their existing site in PA, a newly constructed site in PA, and two contract manufacturers in Thailand.
How Did BCS Help?
BCS reviewed many files and data from OTI, conducted a 2 day on-site assessment. We identified and executed 5 critical workstreams that would allow OTI to scale their production to meet their production objectives:
- BCS installed an interim Senior VP manufacturing to lead the effort, provide accountability and oversight, while we assisted in the search for a permanent replacement (we hired a perm replacement 6 months from start).
- Brought in automation expert to evaluate automated device assembly and put a plan in place to address issues identified. Placed temporary engineering resource to assist/drive completion of tasks.
- DoD facility expansion project was not being managed properly. BCS stepped in to provide project management including updating all their project plans from Microsoft Project into SmartSheets, which provided a more user friendly and informative platform.
- Placed experienced BCS manufacturing expert in Thailand to assist in the ramp plan at two contract manufacturers (one existing and one new). There were numerous quality and logistics issues when we arrived on site in Thailand.
Results
- Increased output over 500% while simultaneously reducing COGs
- Regained confidence of DoD on $100MM+ project for construction and commissioning of new manufacturing facility in Pennsylvania
- Automation output increased by over 50%; increased OEE from 20% to 70%.
- Thailand went from 60% rejects to 99%+ quality while expanding capacity from 1.2 million to 6.5 million FG units per month
- Assisted in hiring permanent Senior VP of Manufacturing
“Mark and the BCS team are the one phone call you MUST make when you need fast action and solutions. They worked side-by-side with the team, every day, to address our operations challenges. I’ve used many consulting firms and BCS is like no other. After only 3 months, they turned around our operations, increasing output by over 500% while reducing COGS simultaneously”.
Lisa Niebauer, President Orasure Technologies
