Loaner Process: Why RFID?

Transcription

1 1

2 Loaner Process: Why RFID? Distribution Center running out of real-estate to accommodate growing Loaner business Same Day turn around of hot sets Sterile packaged shelf life tracking Increased us of Loaner program causing high labor usage Requirement for BOM (Enterprise, Kit-level, etc.) presentation to Audit/Shop-floor personnel Paperless Processing Conclusion: As a Process Improvement specialist, my team and I concluded that RFID along with the right process and training will enable us to overcome these pain points. 2

3 Loaner Process: Defined Scope Sterile Packaged Inventory: Item-level tracking of implant parts and cases/kits. Non-sterile Inventory: Case-level tracking of surgical kits. User base: 35 users of RFID-enabled Audit stations 4 Dock-door type installations 35,000+ Sterile implants to be tagged in year Non-sterile surgical kits/sets in year 1 Process workflows include v Receiving v Audit 1 v Replenishment v Confirmation/Audit 2 v Shipping & Fulfillment 3

4 RFID Project: Assets pictures Sterile Kit and Parts Inspection Table with RFID Reader and Antennae Non-Sterile Kit/Case RFID Tag inside Non-sterile Kit/Case 4

5 RFID Project: Select RFID Components Zebra R110xI Avery AD-826 Moto XR 450 Moto AN 400 Moto AN 200 5

6 Loaners Receiving Scan Pallets Through Dock Doors for Expedited Receiving Process Scan Totes Through Decontam Room Entrance for Second Scan Provide Case Tag & Label Encoding Stations 6

7 Receiving Dock Receiving Eval kits and Sets from the field 7

8 Decontam Entrance Kits are run through Decontam area 8

9 Decontam Exit Eval kits and Sets are taken to audit area for inspection 9

10 Audit Stations 10

11 First Audit Process: (non-sterile product-eval sets) Kits are inspected for completeness and orders are created to replenish missing parts for the sets Uncheck here if missing or write off Missing Write Off Operator removes Kit/Case from Cart(s) and places on Workstation KanBan location Part # and Lot # is Read from the Tagged Item to query the SQL tables (BOM Tables) Operator unchecks all Parts with missing quantities Operator enters missing quantity or write-off quantity When complete User clicks Create Orders button Sets are replenished by Operator per current SoP 11

12 First Audit process: (sterile product) Operator removes Kit/Case from Cart(s) and places on Workstation KanBan location S & R Touchscreen app will display Two grids side by side to The grid on the left side will display all tagged items that were shipped for that Kit The grid on the right will display all tagged items that are currently in the Kit with rows color highlighted for the following types of items o Tagged Items that are near expiry o Tagged Items that are were added in the field (by sales consultant) to this Kit 12

13 Second Audit process-rfid: (Sterile and non-sterile product) Verify completeness of set against Router/BOM. Check completeness of paperwork per W-M-S021. If incomplete, give to Supervisor, Lead or Manager. Sign off on appropriate DHR paperwork. Press Put Away icon on screen. Sign into JDE and create put-away tag. Tag set with the put-away tag. Stage set for Put-Away. Scan bar-coded Put-Away task on tag. Scan bar-coded To Location. Scan bar-coded part number and lot number on product label and place set in storage location. 13

14 14

15 Benefits of RFID Re-allocation of Employees from Receiving to Inspection Eliminates Individual Barcode Read of Packages More Immediate Information for Processing Sets Faster Identification and Scheduling of Hot Sets Serialization of sterile packaged implants (UDI Compliance) Automated replenishment and billing process Faster Audit process Paperless Increased Accuracy 15

16 Sterile Loaners Tracking with RFID Optimize Implant Box Process Automated Receiving Station Tag/Reader/Antenna Expiration Date Tracking 16

17 17