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Finding Greater Efficiency in Modern R&D Laboratories
efficiency, n. - the ratio of the effective or useful output to the total input in any system
by David James, Director Manufacturing Innovation, Invetech
Modern Research and Development (R&D) laboratories are constantly striving for efficiency and often look to automation to solve this challenge. While there are ways of optimizing the performance of a laboratory, the processes that are successful in some laboratories are not the most appropriate in others. Therefore the problem arises in figuring out which methods and processes will increase the efficiency of each laboratory.
The approach is often specific to the circumstances of an R&D laboratory. Most laboratories grow organically over time, adjusting to meet a variety of needs and technical developments, i.e. changes in sample handling methods and regulatory requirements. The largest opportunities for improved efficiency, therefore, tend to exist where there has been a significant change in the requirements of the R&D laboratory.
By involving a specialist third party to analyze whether the basic processes used in a laboratory are the most suitable, it is possible to identify and eliminate pinch points and to plan for future changes. Services such as these are often drawn and adapted from advanced models within the engineering and manufacturing industries, using both automated and non-automated approaches.
The Solution to Workflow Efficiency
With staff in modern laboratories witnessing increased pressure through growing workloads and time consuming tasks, scientists have little time to reorganize processes themselves. By outsourcing to a team of experts, who can integrate with laboratory staff to identify causes and analyze problem areas to determine which processes can be changed, laboratories can improve workflow efficiency. The team can then map the processes using state-of-the-art tools and work with laboratory management to determine control strategies. This ensures that the changes take place and future additions to laboratory instrumentation fit seamlessly and efficiently into the new process.
Employing a specialist team ensures that R&D laboratories are provided with sound advice on workflow issues and will find the best solutions for each individual laboratory. In turn, this will provide a more efficient working environment where scientists are able to apply their skills for maximum effect, improving working conditions for laboratory staff and increasing throughput and the quality of results. Furthermore, using an "idea-to-market" service, specialists can identify which processes will improve through automation, design, and manufacture and deliver new bespoke technology to meet this need. Additionally, in situations where automation is not viable, the team will employ models from the engineering and manufacturing industries to reduce pinch points.
Setting an Example
The issue of efficiency is not one that is unique to laboratories but is shared by companies across the spectrum. Therefore, in some cases, it is useful to study models borrowed from other industries, which can be adapted and applied to laboratories in order to solve workflow issues.
For example, one particular model that is applicable to laboratories is "lean manufacturing." The principle of "lean manufacturing" is based upon the notion that eliminating waste from any process will automatically bring about a more efficient process. Such "waste" can be considered additional labor, raw material or equipment. Allowing experts to identify any needless stages in a process, and then refine that process as far as possible, reduces costs and improves efficiency.
Employing this strategy, a thorough analysis and evaluation is made of each process and its efficiency, which includes documenting each person or function that interacts with a technology and taking account of each process that the technology goes through. This information must be obtained before a decision can be made on how best to improve the process.
For example, recently a client requested an additional piece of automated equipment to enable the company to meet customer demand. On closer evaluation it became apparent that, while performing within specification, the overall equipment efficiency of the existing equipment was less than 30%! The main contributors were quickly identified as being poor yield and equipment uptime. A specialist team identified this was due to variable quality of incoming raw materials, poor operator training and poor management of production staff. These were rectified with minimal investment, and the need to purchase an additional machine with all of its associated operating costs was delayed for several months.
Conclusion
In order for laboratories to achieve their optimum efficiency, they must ensure they have considered all factors that may comprise productivity. By using well established methods to identify where waste can be cut from the production process, laboratories can become more economical, efficient and reduce costs long-term.
For more information, contact David James, Director Manufacturing Innovation, Invetech at david.james@invetech.com.au or by phone at +61392117726.
AT A GLANCE
• Processes to improve efficiencies in some labs are not effective in others
• Most labs grow organically over time, adjusting to different needs and technical developments
• Models from other industries can be successfully applied to lab workflow issues
• In order for labs to achieve optimum efficiency, they must ensure they have considered all
factors that may comprise production
ONLINE
For additional information on the company discussed in this article, see Laboratory Equipment magazine online at www.LaboratoryEquipment.com or the following Web site:
• www.invetech.us
Laboratory Equipment
Advantage Business Media
Rockaway, NJ, 07866
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