Ventec Life Systems Increased Production 80x in Four Months

SYSPRO played critical role in Ventec’s ability to pivot for success

Customer

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Customer Profile

Founded in 2013, Ventec Life Systems is a medical device company specializing in life-support ventilators, with more than 140 employees. Its leading product, VOCSN, seamlessly integrates five separate devices including a ventilator, oxygen concentrator, cough assist, suction and nebulizer into one unified respiratory system. Ventec’s history of patient-centric design includes more than 10 care-changing respiratory devices and over 40 patents.

Their Business Challenge

In Spring 2020, the US Government partnered with Ventec and collaborated with a large manufacturer to complete an order for 30,000 ventilators. This required Ventec to dramatically increase its production volumes and change business processes to achieve the necessary flexibility and customization.

The Solution

Ventec Life Systems produced 80 times the number of devices it would ordinarily produce, completing the order in just 154 days. By using SYSPRO across its operation, Ventec was able to adapt and change its business processes to achieve success.

The Outcome

At the start of the COVID-19 pandemic, Ventec collaborated with the manufacturer to rapidly scale up production of critical care ventilators. In one month, the teams went from an introductory phone call to delivering life-saving technology to frontline medical heroes. The full federal order of 30 000 ventilators was completed in just 154 days, with one unit completed about every seven minutes.

“We worked with SYSPRO and Systems Advisory Services to alter our SYSPRO solution to enable a three-shift operation 24 hours a day, seven days a week. SYSPRO’s flexibility allowed us to adapt and change our business processes to make that possible.”
– Mike Long, Vice President of Operations, Ventec Life Systems.

SYSPRO 8 Benefits to Customer

Increased rate of manufacturing by 80 times between May and August 2020
Streamlined shop floor operations with customized panes for job processing
Increased productivity through an engaging, simplified user experience
Access to a vast quantity of data led to improvements and a higher quality product
Success opened up opportunities for further growth

Ventec engineers created a new configuration of a critical care ventilator at record speed to meet the escalating need to fight COVID-19. Production began in April 2020, with Ventec and the manufacturer teaming up to systematically analyze each process to see how it could be divided into multiple processes that operated in parallel. Ventec also had to work closely with its suppliers to ensure it had the components required to manufacture the new configuration.

Ventec worked with SYSPRO to understand and address the barriers to the project, quickly developing the ability to predict impediments. The existing customizations in its systems supported a parallel build process which had to be modified into a flow operation. For example, a 90-minute operation performed by one person was broken up across 12 stations. This type of adaptation enabled Ventec to run a three-shift operation, 24 hours a day, seven days a week. SYSPRO’s flexibility made that possible by allowing Ventec to adapt its business processes.

The company uses SYSPRO throughout its organization, from Material Requirements Planning to purchase orders, inventory management, inventory control, lot serial tracking, Work in Progress, shipping logistics and sales order processing. The data generated by SYSPRO drives Ventec’s sales force automation management and post-market servicing.

Key success factors included communicating effectively with staff and allocating accountability. By engaging the workforce to understand the requirement and the goal, people willingly worked double shifts without question.

“The solid collaboration between Ventec, SYSPRO and SAS enabled rapid iteration of customizations, which was key. Once you have the right tools and people and are willing to take advantage of all 24 hours in the day, it’s amazing what you can get done.”
– Mike Long, Vice President of Operations, Ventec Life Systems.

“Previously, we produced about 150 units a month. Ninety days into the project, in July, we reached a target of 12 000 devices for the month. All in all, we increased our rate of manufacturing by 80 times between May and August 2020.”
– Mike Long, Vice President of Operations, Ventec Life Systems.

“We are committed to maintaining increased production capacity for as long as is needed to ensure frontline healthcare workers have the necessary tools to save lives.”
– Mike Long, Vice President of Operations, Ventec Life Systems.

Achieve business success with SYSPRO ERP

SYSPRO is a leading, global Enterprise Resource Planning (ERP) software provider, specializing in key manufacturing and distribution industries. SYSPRO’s ERP solution empowers customers to take the next step – whether it is expanding into new territories, adding new product lines, transforming business processes, or driving innovation.

Ventec Life Systems Increased Production 80x in Four Months

SYSPRO played critical role in Ventec’s ability to pivot for success

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