In the fast-evolving world of medical device manufacturing, efficient asset management and maintenance are critical to ensuring operational excellence and product quality. TERUMO Vietnam implements CMMS EcoMaint, a powerful Computerized Maintenance Management System (CMMS) developed by Vietsoft, to streamline its maintenance operations and optimize asset performance at its state-of-the-art facilities in Vietnam. This article explores how Terumo Vietnam, a global leader in medical technology, leverages the advanced features of CMMS EcoMaint to enhance productivity, reduce downtime, and support its mission of “Contributing to Society through Healthcare.”

I. About Terumo Vietnam: A Global Leader in Medical Technology

Terumo Vietnam is a key subsidiary of the Terumo Corporation, a renowned Japanese multinational founded in 1921 in Tokyo. With a global workforce of over 30,000 employees, Terumo operates in more than 160 countries, delivering innovative medical solutions that span vascular intervention, cardiovascular surgery, blood transfusion, cell therapy, and essential clinical products. The company’s commitment to quality, innovation, and societal impact has made it a trusted name in healthcare worldwide.

In Vietnam, Terumo operates three distinct entities:

·        Terumo Vietnam Co., Ltd. (Manufacturing Plant): Located at Lot 44A-B-C, Quang Minh Industrial Park, Chi Dong Town, Me Linh District, Hanoi, this facility, established in 2006, specializes in producing high-quality medical devices and consumables. With a $96.5 million investment, it is a 100% Japanese-owned export-oriented enterprise.

·        Terumo Vietnam Medical Equipment Co., Ltd. (Commercial Entity): Based on the 14th floor of the Geleximco Building, 36 Hoang Cau, O Cho Dua Ward, Dong Da District, Hanoi, this entity, established in 2012, focuses on distributing Terumo’s medical products across Vietnam.

·        Terumo BCT Vietnam Co., Ltd. (Manufacturing Plant): Operating since 2014 at Long Duc Industrial Park, Long Thanh District, Dong Nai, this facility produces blood bags and automated blood collection systems (Trima), contributing to advanced blood component and cellular technologies.

Terumo Vietnam’s second manufacturing plant in Quang Minh, operational since June 2013, spans over 23,000 square meters and incorporates cutting-edge production lines adhering to Japanese quality standards. As part of its expansion strategy, the company has invested significantly in modernizing its facilities and adopting sustainable practices, such as solar energy systems and waste management initiatives, to align with its environmental responsibility goals.

II. Why TERUMO Vietnam Implements CMMS EcoMaint

 

The decision to implement CMMS EcoMaint reflects Terumo Vietnam’s proactive approach to modernizing its maintenance processes and ensuring operational efficiency. With the expansion of its second factory and the increasing complexity of its production equipment, Terumo Vietnam recognized the need for a robust, scalable solution to manage its assets effectively. Traditional methods, such as Excel-based tracking or paper-based maintenance logs, were no longer sufficient to handle the intricate requirements of a high-tech medical device manufacturing facility.

TERUMO Vietnam implements CMMS EcoMaint to address several critical challenges:

• Complex Equipment Management: Managing a large number of sophisticated medical production machines, which Excel or manual systems could not handle efficiently.
• Minimizing Unplanned Downtime: Reducing unexpected equipment failures to maintain production continuity and meet stringent quality standards.
• Cost Control: Optimizing maintenance and inventory costs to improve profitability.
• Regulatory Compliance: Ensuring equipment reliability to meet global medical standards and certifications.
• Sustainability Goals: Supporting energy-efficient operations and environmental initiatives through precise equipment monitoring.

By partnering with Vietsoft, a trusted provider of CMMS solutions with over 20 years of experience in Vietnam, Terumo Vietnam embarked on a transformative journey to digitize its maintenance operations and achieve operational excellence.

III. Key Features of CMMS EcoMaint Deployed at Terumo Vietnam

CMMS EcoMaint is a comprehensive, web-based maintenance management solution designed to optimize asset management, streamline workflows, and enhance operational efficiency. Tailored to meet the needs of industries with complex equipment, such as medical device manufacturing, EcoMaint offers a suite of features that have proven instrumental in Terumo Vietnam’s operations.

1. Comprehensive Asset Management

EcoMaint enables Terumo Vietnam to manage its entire asset lifecycle, from procurement to disposal. Key functionalities include:

• Asset Information Storage: Detailed records of each asset, including model, specifications, maintenance history, and technical documentation.
• Hierarchical Asset Structure: Organizes equipment in a tree-like structure for easy tracking of components and subsystems.
• QR Code Integration: Each asset is tagged with a QR code, allowing technicians to access information instantly via mobile devices.

2. Preventive Maintenance Scheduling

EcoMaint automates the creation of maintenance schedules based on time intervals or operational metrics (e.g., machine runtime hours). This feature helps Terumo Vietnam:

• Plan regular maintenance to prevent unexpected breakdowns.
• Receive automated reminders for upcoming maintenance tasks.
• Reduce downtime by proactively addressing potential issues.

3. Work Order Management

The system streamlines work order creation and tracking, enabling:

• Automated Work Orders: Quick generation of maintenance tasks based on detected issues or scheduled plans.
• Real-Time Tracking: Monitoring the status of work orders (e.g., pending, in progress, completed) to ensure timely completion.

4. Inventory and Spare Parts Management

EcoMaint optimizes inventory management by:

• Tracking spare parts and materials in real time.
• Issuing alerts when inventory levels fall below defined thresholds.
• Streamlining procurement by generating purchase proposals based on maintenance schedules.

This ensures that Terumo Vietnam maintains adequate stock levels without overstocking, reducing costs and waste.

5. Detailed Reporting and Analytics

EcoMaint provides a robust reporting module with customizable dashboards, offering insights into:

• Equipment Performance: Metrics such as Overall Equipment Effectiveness (OEE) to evaluate asset efficiency.
• Maintenance Costs: Detailed breakdowns of planned vs. unplanned maintenance expenses.
• Downtime Analysis: Identifying causes of downtime to implement corrective measures.
• Inventory Turnover: Monitoring stock rotation to optimize inventory management.

These reports empower Terumo Vietnam’s management to make data-driven decisions, enhancing operational efficiency and cost control.

6. User-Friendly Interface and Mobile Access

Designed for ease of use, EcoMaint’s intuitive interface and mobile app ensure that technicians, regardless of technical expertise, can:

• Access asset information and maintenance tasks on the go.
• Scan QR codes to retrieve equipment details instantly.
• Submit real-time updates, improving communication between production and maintenance teams.

IV. Benefits of CMMS EcoMaint for Terumo Vietnam

By implementing CMMS EcoMaint, Terumo Vietnam has unlocked significant operational and financial benefits, aligning with its goals of quality, efficiency, and sustainability. Based on Vietsoft’s case studies and industry benchmarks, the following outcomes are anticipated:

• Increased Productivity: Up to 20% improvement in overall productivity due to reduced downtime and optimized maintenance workflows.
• Reduced Downtime: A potential 20% reduction in unplanned downtime, ensuring continuous production and adherence to delivery schedules.
• Cost Savings: 5-15% reduction in maintenance costs through proactive maintenance and efficient inventory management.
• Extended Equipment Lifespan: Up to 10% increase in asset longevity by addressing issues before they escalate.
• Inventory Optimization: 10-20% reduction in spare parts inventory, minimizing waste and storage costs.
• Enhanced Compliance: Improved tracking and documentation to meet stringent medical industry regulations.

These benefits directly support Terumo Vietnam’s mission to deliver high-quality medical devices while maintaining cost efficiency and environmental responsibility.

V. Implementation Process at Terumo Vietnam

TERUMO Vietnam implements CMMS EcoMaint at its second manufacturing plant in Quang Minh Industrial Park, following a structured deployment process to ensure seamless integration and maximum impact. The implementation, initiated in 2023, was completed in just three months, demonstrating Vietsoft’s expertise in delivering rapid and effective solutions. The key steps included:

1. Needs Assessment and Planning:

o    Vietsoft’s consultants conducted a thorough assessment of Terumo Vietnam’s maintenance challenges, identifying key pain points such as equipment downtime and inventory inefficiencies.

o    A tailored implementation plan was developed, prioritizing critical functionalities like preventive maintenance and real-time reporting.

2. Data Preparation and System Setup:

o    Terumo Vietnam compiled detailed asset data, including equipment lists, maintenance histories, and spare parts inventories.

o    Vietsoft’s team coded and categorized assets using a structured naming convention, ensuring clarity and consistency.

o    The system was configured on a cloud-based platform, enabling secure access from web and mobile devices.

3. Training and User Adoption:

o    Vietsoft provided targeted training sessions for Terumo Vietnam’s maintenance team, production staff, and management, completed in a single day per group.

o    The user-friendly interface and mobile app ensured quick adoption, even among staff with limited technical expertise.

4. Testing and Go-Live:

o    Rigorous testing was conducted to verify system functionality and data accuracy.

o    The system went live, with Vietsoft providing ongoing support to address any issues and ensure smooth operation.

5. Continuous Improvement:

o    Post-implementation, Terumo Vietnam leverages EcoMaint’s analytics to monitor performance metrics and refine maintenance strategies.

o    Regular updates and support from Vietsoft ensure the system evolves with Terumo’s growing needs.

 

VI. Real-World Impact: Early Results at Terumo Vietnam

Since implementing CMMS EcoMaint, Terumo Vietnam has reported significant improvements in its maintenance operations. Early data indicates:

• 42% Reduction in Downtime
• 20% Reduction in Maintenance Costs
• 76% Decrease in Unplanned Repair Incidents

 

VII. Why CMMS EcoMaint is Ideal for Terumo Vietnam

EcoMaint’s flexibility and scalability make it an ideal fit for Terumo Vietnam’s unique needs. The system’s cloud-based architecture allows seamless access across multiple facilities, supporting Terumo’s multi-site operations in Hanoi and Dong Nai. Its integration with IoT sensors aligns with Terumo’s commitment to sustainability, enabling precise monitoring of energy-intensive equipment to reduce consumption and emissions.

Moreover, EcoMaint’s ability to operate independently or integrate with existing ERP systems ensures compatibility with Terumo’s established workflows. The system’s multilingual support (English and Vietnamese) facilitates collaboration between local staff and Japanese management, enhancing communication and efficiency.

 

VIII. Supporting Terumo Vietnam’s Sustainability Goals

Terumo Vietnam’s commitment to environmental responsibility is evident in its adoption of solar energy, waste management systems, and energy-efficient practices. CMMS EcoMaint complements these efforts by:

• Optimizing Energy Use: Monitoring equipment performance to identify and address inefficiencies, contributing to Terumo’s goal of reducing CO2 emissions.
• Reducing Waste: Streamlining inventory management to minimize excess stock and waste.
• Enhancing Enhanced Equipment Lifespan: Extending the lifespan of machinery, reducing the need for frequent replacements and conserving resources.

These features align with Terumo Vietnam’s achievement of the “5-Star Green Energy User” certification from the Hanoi People’s Committee in 2023, recognizing its leadership in sustainable industrial practices.

 

IX. Conclusion: A Strategic Step Toward Operational Excellence

TERUMO Vietnam implements CMMS EcoMaint as a strategic move to enhance its maintenance operations, boost productivity, and align with its mission of delivering high-quality medical solutions. By digitizing asset management and maintenance processes, EcoMaint empowers Terumo Vietnam to minimize downtime, control costs, and maintain compliance with global standards. The successful implementation at its Quang Minh facility underscores Vietsoft’s expertise in delivering tailored, high-impact solutions for Vietnam’s manufacturing sector.

For enterprises seeking to embark on their digital transformation journey, CMMS EcoMaint offers a proven, user-friendly, and cost-effective solution. Discover the CMMS EcoMaint solution here.

Contact us for consultation via hotline: 0986778578 or email: sales@vietsoft.com.vn.