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Navigating Rapid Expansion in Manufacturing: A Conversation with Gábor Mikó, Manufacturing Director at MedRes


Can you tell us about the challenges your team faced last year?

In 2022, due to a significant increase in demand, we doubled our output. This posed a number of challenges for our infrastructure and staff. We grew our staff by 30%. We faced several obstacles, but we were able to come up with solutions to address these.


What strategies helped address the challenges?

We constructed a second cleanroom production area. We deployed semi and fully automated equipment to support or replace manual processes. To better support the revised production process, we also implemented an electronic documentation system replacing the previous paper-based system. Furthermore, we reorganized the production line with a LEAN approach. We expanded our workforce by 30% and introduced a new bonus system to motivate employees.


What was the preplanning and preparation process like?

A long planning process began the prior year to implement the desired changes. Analysis, measurements and adherence to ISO standards were necessary to ensure a high-quality outcome. Customer satisfaction was also a top priority, and so we prioritized communication with our clients and internal stakeholders. Recruiting and training was another top priority, keeping us busy for the first half of the year. Another long lead item was production equipment. New equipment was ordered and some of it had to be further customized to our needs. This was followed by operator training before we could fully utilize the new technology on our production lines. This was a worthwhile investment of time and effort, as we have since been utilizing the expanded infrastructure and staff to accelerate our manufacturing processes.


What automated equipment did you install?

In order to increase comfort and efficiency in production, we have procured semi- or fully automated equipment such as pulse pouch welders, cable strippers, cable cutters, PVC pipe separators, cutters and precision glue dispensers, portable UV workstations, and automatic leak testers. Manual work is still necessary for many tasks and device assembly, but this equipment can help streamline the process.


How did you tackle the challenges posed by rapid growth in headcount?

Both new and existing employees had to get familiar with new processes, techniques, fixtures and equipment in order to keep up with the increased production volume. Carefully designed training was key to success. The increase in production volume has led to an expansion in the volume and complexity of documentation, as well as an increase in the number of tasks that needed to be completed and documented. This has been especially challenging for the veteran employees who have been with the company for years, in some cases for over a decade. Nevertheless, through the implementation of training programs and visual instructions and guides posted throughout the workplace, the staff has been able to adjust to the new situation.


What is the training process for new colleagues joining the production team?

The training of a new hire depends on the position they are hired for. We typically hire process engineers, product line managers, technicians and different levels of operators to support growth. New operators are typically started on easier processes and are mentored by an experienced member of the team. As operators become proficient in more processes, they see financial benefits and opportunities for advancement.


In closing, can you please summarize what the benefits of working in MedRes manufacturing team are?
We set up new hires for success through training and mentoring. we maintain a family-like atmosphere, we look out for each other. Employees are encouraged to ask question and make suggestions and we’ll work together to find solutions. We highly value our colleagues and offer career advancement opportunities, which is why we have low employee turnover.