By replacing its legacy production monitoring system with Nulogy Smart Factory, LetsGetChecked increased cycle times at its Dublin facility by 13% and drove process improvements throughout the organisation.
Founded in 2015 and co-headquartered in Dublin and New York, LetsGetChecked is a global healthcare solutions company that provides tools to manage health from home through health testing, genetic sequencing, virtual care and medication delivery for a wide range of health conditions. LetsGetChecked’s end-to-end model includes manufacturing, logistics, lab analysis, physician support, and prescription fulfillment.
The LetsGetChecked team in Ireland previously adopted a production monitoring system that ultimately yielded inadequate results. In its place, LetsGetChecked wanted a new system that could provide complete real-time data visibility into plant performance, which in turn could help deliver insights into how their teams could improve production and fulfillment processes.
After switching to Smart Factory, LetsGetChecked saw its production cycle times jump by 13%—leading to more efficient production of testing kits and greater fulfillment capacity.
LetsGetChecked produces a variety of health testing kits, each with their own distinct cycle times and kit assembly processes. Production Planner Rahul Alagusundaram explained that through Smart Factory, the LetsGetChecked team now has access to actual cycle time data during production, and over the course of two years has leveraged that data for incremental process improvements.
“This year, we’ve come to a stage where we are actually over performing at times,” Alagusundaram says. “The data from Smart Factory makes it a lot easier for us to re-analyse our processes and raise our benchmarks.”
Implementing Nulogy Smart Factory has also given the LetsGetChecked team greater clarity into downtime causes, allowing them to take action more quickly and effectively. By gaining complete visibility into their production through visual factory scoreboards, production staff can see if their production is performing ahead or behind schedule, identify issues and attribute them accordingly for future improvement.
“[Smart Factory] has given us a clear picture on how the downtime is influencing the production of kits, as well as how our operators factor into overall performance,” Alagusundaram says. “We were able to differentiate between the factors affecting how our kits are being produced and fulfilled.”
Not only has Smart Factory has driven positive impacts on the plant floor, helping the team analyse downtime and process metrics from the system is also improving the work of different departments throughout the facility.
“With Smart Factory, everything is on one big screen: we’re able to instantly identify where we are lacking or where we are leading,” says Rahul Alagusundaram.
Further, the data from Smart Factory has helped the planning and production teams work together to plan batches and estimate times of completion, which in turn helps the quality team plan the labor needed to inspect each batch.
Lastly, the production data drawn form Smart Factory feeds into measuring the plant’s key performance indicators (KPIs), such as downtime reduction and its associated impacts.
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Smart Factory is being used by the fulfillment team to measure the performance of its autobagger machinery. “The capability will prove useful for us to analyse our capacity in the future.”
LetsGetChecked, Demand Planner & Analyst
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