“Switching horses midstream” is an idiom that means to abruptly change leaders or strategies in the middle of a crucial task, often suggesting that such a change is not a good idea and could lead to problems or failure. It’s based on the idea that trying to swap horses while crossing a river would be risky and impractical.

Sometimes, however, you just have to concede that you’re going to get your boots wet.

Such was the case recently when a pharmaceutical manufacturer contacted machine builder Norwalt Automation Group in Randolph, NJ. The manufacturer had hired another systems integrator to design and build a set of three automated machines to assemble a product requiring FDA approval with an aggressive deadline.

Unfortunately, it quickly became clear that there was a problem. When the first machine was delivered, it wouldn’t run for a minute without stopping. Three operators were required to run it, and the machine was operating with an overall equipment effectiveness (OEE) of just 10 percent. (OEE measures how efficiently production equipment is utilized, encompassing availability, performance and quality.) The second and third machines had yet to be completed.

The manufacturer knew it was in trouble. The project manager realized the system would not be ready in time for an established date for FDA inspectors to review the equipment. Without FDA approval, the manufacturer would not be able to deliver on a $20 million contract.

To save time, engineers incorporated long-lead-time components from the current system into the new one. Photo courtesy Norwalt Automation Group

Running out of time, the manufacturer contacted Norwalt. Mike Seitel, Norwalt’s chairman and CEO, visited manufacturer’s plant the next day.

After examining the existing machine and the partially completed ones, Seitel recognized the challenge that this project presented. “The concept was wrong. There weren’t enough stations in the base system to do the assembly properly,” recalls Seitel, who has been with the company since 1987.

Despite the hurdles the project presented, Seitel knew Norwalt was up to the task. “Our ability to think and move quickly is one of our major strengths,” he says.

Norwalt has been designing and building custom automation systems since 1971. The company’s customers include Abbott Laboratories, Becton Dickinson, Gillette, Terumo Corp. and Tessy Plastics.

Norwalt has built both continuous motion and indexing machines to assemble products with two or as many as 10 or more parts. The company has experience integrating numerous processes into its systems, including decorating, leak testing, induction welding, conduction welding, ultrasonic welding, labeling, vision inspection and dispensing. Its machines have produced at rates ranging from 15 to 1,200 parts per minute.

Norwalt engineers had just eight weeks to design and build an automated assembly line for a pharmaceutical product. Photo courtesy Norwalt Automation Group

Coming to the Rescue

Norwalt’s engineers had just eight weeks to design and build three assembly machines. Working against the clock, Norwalt’s team rethought the manufacturer’s entire process and, in less than 24 hours, addressed the problems.

Norwalt’s engineers quickly redesigned the system, incorporating long-lead-time components from the current system to save time. In addition, Norwalt’s supplier partnerships allowed all the newly designed components to be fabricated in the most expedient manner necessary to meet the deadline.

Thanks to Norwalt’s agile approach, one machine was delivered five days ahead of schedule. The second and third machines came in one day ahead of the agreed-upon delivery date. This gave the manufacturer even more time to ensure everything was in place for the all-important FDA visit to secure approval and fulfill its contract.

The system developed by Norwalt reduced the labor needed to run the machine by 66 percent. Upon installation, the team could see the machine was up to speed within the 24 hours. It ran for hours at a time without stopping at 97.6 percent OEE and at a rate of 156 times faster than the original version. The system now runs at a 98 percent OEE, in a lights-out setting, enabling the manufacturer to focus on other tasks with its labor force.

Norwalt’s heroics fostered a long-term relationship with the manufacturer. Since then, Norwalt has worked with the manufacturer on additional projects.

Norwalt has been designing and building automated assembly systems since 1971. Photo courtesy Norwalt Automation Group