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Contract Manufacturing Firm Coastal Life Technologies Completes First Phase of Warehouse Improvement Initiative

Coastal Life Technologies, a San Antonio-based contract manufacturing outsource provider focused on delivering turn-key services for medical devices, has completed the first phase of its warehouse improvement initiative. The improvements are based on Lean Principles and mark the first application of Lean to a process outside of manufacturing.

After receiving training in Lean principles and techniques, CLT’s team mapped out the material handling process to identify baseline performance and highlight opportunities for improvement. The team used Spaghetti Maps, Pareto analysis and visual management tools to modify the layout of the raw material storage area. Some key improvements include:

  • Increased the number of locations by 28% in the same footprint for better utilization of space
  • Improved ergonomics and inventory organization
  • Added use of hand held scanners to make real time inventory transactions, reducing errors and cutting component picking time by 50%
  • Increased Pick to Order efficiency of 14%

Two other Warehouse projects are underway and scheduled for completion in the next few months. CLT plans to continue to use Lean techniques on support activities as part of its overall continuous improvement strategy.

Pam Peters, CLT Logistics Manager commented, “We needed a better way to organize and streamline our raw material storage and handling. Because of our growth, we needed to focus on the process from start to finish.”

Centrally located in San Antonio, Texas Coastal Life Technologies, Inc. (CLT) is a single-source solution for medical device manufacturers who want to increase productivity and decrease time to market in a cost-effective and quality-controlled environment. CLT specializes in the assembly, packaging and sterilization of single-use surgical devices, and offers streamlined solutions from designing and engineering a product, warehousing, order fulfillment, distribution and shipping. CLT is ISO 13485:2003 certified with ISO Class 8 cleanrooms.

Final Assembly & Sterile Packaging

CLT can perform a variety of assembly processes and packaging operations in our 8,000 square foot ISO Class 8 clean room. Our primary expertise is in assembling and packaging sterile, single-use, disposable surgical devices.

We engineer processes and streamline manufacturing to allow for greater efficiencies, lowering cost to our customers. Our team reviews the specific assembly requirements and selects the best systems for the product. Lean Manufacturing tenets such as pull systems, back flushing, and Kanbans are utilized to maintain and maximize production control and efficiency.

Product quality should not depend on inspection after production; it should be inherent to the design and manufacturing processes. Quality is always a part of our process engineering. A quality assurance plan suited to your product requirements will be established, including the quality benchmarks used in our continuous improvement efforts.

Process validation is integral to the final packaging of all sterile devices that we manufacture. We can package in pouches or trays depending on what is best suited for your product. CLT continues to monitor the packaging process as part of our ongoing quality plans to ensure package integrity.