MAKING IMPOSSIBLE POSSIBLE

In April 2020, the Indian Government demonstrated its trust in Bharat Electronics Ltd (BEL) and its agile production system capability when it placed its order for 30,000 ICU ventilators, which were produced during the lockdown period. Due to supply chain disruptions, BEL received considerable assistance from different government bodies and managed to overcome numerous hurdles to accomplish the project. On August 14, 2020, the production of 30,000 ventilators was successfully completed, marking a significant achievement.

Overcoming countless challenges

BEL faced key challenges as it had entered into critical care medical equipment manufacturing with no prior experience, domain knowledge, or infrastructure.

The company had set a target of designing and delivering 30k units within a short span of just 90 days. Importing critical components for medical equipment was challenging due to export restrictions and overseas domestic demand, which resulted in dynamic pricing and unpredictable lead times.

Subcontracting work packages to MSMEs had become necessary due to the closure of the nationwide lockdown. Logistics issues arose due to cross-border traffic and other related factors.

Meeting various technical parameters during the concurrent production phase was difficult as the CV200 Ventilator was continuously being upgraded by the design teams (DRDO, Skanray, and BEL) to cater to indigenization efforts of critical components. Clinical trials and approvals by DGHS were required for the new launch of the CV200 ventilator.

Additionally, there was a need to realign the manufacturing facility to meet production of medical-grade ICU ventilators instead of defence products.

CV 200 Ventilator System

Approaches resorted

The creation of a War Room helped BEL in making faster and dynamic decisions, which led to the success of the project. Identifying TOT partners and co-locating the BEL and TOT teams helped in achieving the project goals. Infrastructure creation and realignment were done to support the production of critical care medical equipment. Cross-functional task force teams were formed with specific tasks to ensure efficient and effective production. Obtaining statutory certifications was a crucial step in the success of the project. Multiple/alternate sourcing for critical and long-lead parts ensured uninterrupted production. Timely indigenization of imported parts helped in reducing the dependence on foreign suppliers.

Production at multiple business units helped meet the high demand for medical equipment. Online training of medical professionals for usage of the medical equipment was crucial for the success of the project.

Additionally, a pan-India installation network was established to ensure the timely installation of care medical equipment.

Results that made it all worthwhile

The successful manufacturing of 30,000 ventilators in a record time of just 90 days was a significant achievement. An additional order for the manufacturing of 2,000 ventilators from GMSCL, Gujarat, was received in the year 2021-22, which was executed successfully. The experiences in the manufacturing of ventilators led to the formation of a separate business vertical for medical equipment.

The success of the project boosted confidence in manufacturing other medical devices like oxygen concentrators, hemodialysis machines, and patient monitoring systems, among others.

The Indian Government entrusted BEL with an order for the manufacturing of 17,000 oxygen concentrators, which was executed successfully in the year 2021-22.

BEL also took up the contract manufacturing of SPOC controller boards for Bharat Forge Ltd. Indigenization of components that were previously sourced from other countries helped in reducing dependence on foreign suppliers.

Delegates from South African countries visited BEL and found potential opportunities to export medical products, which highlights the positive impact of the project.

The successful manufacturing of critical care medical equipment, particularly ventilators, has led to precious human lives being saved across the country. The project has enhanced the healthcare infrastructure in society, which is a significant resource impact.

The existing defence manufacturing infrastructure was effectively converted into a healthcare manufacturing facility without a huge investment. BEL arranged online training sessions on ventilator usage for healthcare professionals for a period of 18 months, which enhanced their competency.

The indigenization of critical parts has resulted in cost savings and has created employment opportunities. The project has enhanced the knowledge and competency of Indian suppliers in the manufacturing of healthcare components.

The success of the project has provided a thrust toward AtmaNirbhar Bharat in healthcare equipment. It has established India as a major hub for ventilator manufacturing.

The importance of creating a War Room for faster decision-making was highlighted. The benefits of indigenization and alternate vendor development were emphasized, even if it meant differential pricing.

Collaborative teamwork was identified as a key to success. Challenges and proposed solutions should be presented to top management for guidance and decision-making.

Total employee involvement once again proved to be essential for the success of any project. Resource optimization and multiple production line setups helped meet production takt time. Follow-up teams aided in coordinating and expediting deliveries from vendors. Digital dashboards were effective for project monitoring. Breaking down critical assemblies into smaller chunks was found to be helpful.

The project enhanced BEL's domain knowledge in medical equipment manufacturing. Methodologies for handling crash projects and critical projects during national emergencies were developed. The mass manufacturing of medical equipment was successfully carried out. Multiple sources for critical and long lead-time parts were established.

Source: Bharat Electronics Ltd

Changappa N R                         Manager, Purchase/MM Export Manufacturing-SBU Bharat Electronics Ltd changappanr@bel.co.in

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