How we transformed a MedTech company's design process

The Design Head at Merck often found himself thinking this as he tried to balance all his responsibilities. He had to manage his team, oversee projects, and ensure everything ran smoothly. However, one big problem kept coming up: collaboration.

Merck was having a tough time with their design vendors. Communication could have been better, support could have been faster, and quality could have been more consistent. These issues were causing delays and making it hard to meet deadlines. It was like trying to balance the Jenga tower on a shaky table.

When Merck contacted Design Works (TDW), we immediately understood the problem. We knew how these issues could mess things up. Our approach was straightforward: we analyzed the problems and understood how everything worked together. We used a six-eye review process to avoid communication issues, ensuring every piece was in the right place.

Even though Merck felt better, they were still worried about quality and reliability. We reassured them that our team was highly skilled and had strict quality control measures and consistent standards. We also used strong security measures, like 256-bit encryption, to keep data safe and had backup automation to prevent data loss. It was like we had a plan to stabilize the wobbly Jenga tower.

Merck was still cautious because they had other vendors with similar services. We explained what made us different: our focus on streamlining the design process. We didn't just design products; we automated repetitive tasks to save time and effort. Our automation was like removing the unstable blocks and reinforcing the tower with solid, unmovable pieces.

This interested Merck. Our three-step approach to design automation involved understanding Merck's workflow, creating custom CAD automation scripts for repetitive tasks, and integrating intelligent applications to optimize the workflow further. This allowed Merck's team to focus more on strategic design thinking, strengthening and stabilizing the tower.

We shared a success story about helping Larsen & Toubro (L&T) Construction. L&T had issues with their manual formwork process, which was slow and error-prone. Our solution automated the creation of Bill of Materials (BOM) and Elevation Drawings, cutting the time needed by up to 60%, reducing errors, and speeding up their projects. It was like replacing weak blocks with strong ones, making their Jenga tower taller and sturdier.

Impressed with our approach, Merck decided to look closer. Their design requirements were a digital 3D model of their custom system, including the chassis, piping, and pressure vessel. They also needed system general assembly drawings and fabrication drawings for all components. Additionally, they required separate lists for all components in the Bill of Materials (BOM) and a 3D visualization of the entire system.

We confirmed we could handle all these requests. Confident in our ability to improve their design process, Merck was excited to move forward. They believed our solutions could benefit their operations and were eager to work together to achieve their design goals. With our help, Merck felt like their Jenga tower was finally stable and robust, ready to reach new heights.

Team Expansion

Our journey began with a small but ambitious team of 2-3 members. We were thrilled about having our first client but quickly realized we needed more hands to handle all the work.

The task ahead was straightforward: we needed to expand our team quickly.

The strategy was straightforward – hire experienced professionals with a solid background in design. Once we started our hiring process, we encountered a significant challenge. The professionals we interviewed were typically mid-30s, and their salary expectations exceeded our budget. It felt discouraging, as if we were stuck in a never-ending cycle of interviews.

Recognizing our budget constraints, we decided to change our approach. Instead of focusing solely on experienced professionals, we opened our doors to fresh graduates. This decision was risky. Freshers, while enthusiastic, often needed more practical experience. However, we saw an opportunity to mould these young minds and create a team that could grow with us.

New Horizons

Hiring freshers brought new energy to our company, but the real challenge was training them quickly. To address this, we created a comprehensive training program focusing on three main areas: understanding client requirements, learning industry standards, and developing skills.

The process was challenging. However, the freshers brought excitement, new ideas, and energy to the team, often leading to creative solutions. In the end, our hard work paid off. This experience taught us valuable lessons in adaptability, resourcefulness, and continuous learning.

Beyond Expectations

As we gained experience in MedTech system design and consistently delivered excellent results, we realized we could do more than merely meet expectations. With growing expertise, we aimed to redefine what was possible for our clients.

Understanding our clients' design processes deeply, we sought ways to work smarter, not just harder. We noticed the repetitive nature of specific tasks, such as creating Piping Weld Log drawings, which required generating hundreds of drawing sheets per project. This time-consuming process prompted us to find a more efficient solution.

Efficiency and Success

We saw an opportunity to work smarter by automating these tasks. Determined to save time and improve efficiency, we brainstormed and tested solutions for weeks. Finally, we had a breakthrough, successfully automating 60-70% of the Piping Weld Log drawing process. This efficiency helped our clients minimize lead times, gain a competitive edge, win more projects, and increase revenue.

By leveraging technology and building on our expertise, we improved efficiency and helped our clients achieve more tremendous success in less time.

System Design Process

In our collaboration with the client, we handle a variety of activities to ensure the best quality and efficiency in designing and manufacturing TFF systems. Below is an overview of these activities to show each step of the process.

Our design team starts by analysing the P&ID (Process and Instrumentation Diagram) to understand the client's requirements for the TFF system. This involves understanding the processes, different components, and their functions, etc.; with a clear understanding of the system, our team begins developing conceptual layouts for the TFF system.

Fabrication Process

After finalizing the conceptual layout, the team creates a 3D model using CAD software. They refer to the P&ID to create a detailed 3D assembly model of the system, ensuring compliance with industry standards like ASME BPE. This helps to visualize the system and identify any potential issues early on.

Once the 3D assembly model is completed and approved by the client, the design team moves on to create detailed 2D drawings required for manufacturing the TFF system. These drawings provide precise instructions for fabricators and technicians, illustrating how each component should be manufactured and assembled.

Future Innovations

Just as a robotic bricklayer transforms the work of a mason, Our formwork automation software revolutionized the construction design process for L&T. This innovative solution is a testament to our commitment to addressing real-world challenges with cutting-edge technology, ensuring greater efficiency, reduced errors, and enhanced project outcomes.

By embracing automation, construction companies can now enjoy a streamlined, efficient, and error-free formwork design process, much like a construction site that benefits from the precision and speed of a robotic bricklayer.

• With the adoption of these technologies, We seek to:

• Undertake Larger Projects

• Optimize Workflows

• Explore Innovation

• Secure More Projects