Case Study
Smileactives®
About the Work
Oral Care Products, is a leading research and development company for human and companion-animal oral care technologies for the Consumer and Professional dental markets. The team at Oral Care Products turned to Build by Boyd to assume the long-term manufacturing responsibilities for Smileactives®, Oral Care Product's at-home teeth whitening system, which was already an established product.
Process Development & Validation
Equipment Transfer
Process Optimization
Process Validation
Manufacturing
Automated ManufacturingPackaging
Supply Chain Management
Alternate Supplier QualificationSupply Chain Management
Process Development & Validation
The Smileactives® manufacturing transfer program required the team at Build by Boyd to relocate commercial scale mixing, filling, and labeling manufacturing lines from the Oral Care Products manufacturing facility into ours. The team constructed new wet labs for research and development, inspection, and testing and then transferred the associated lab equipment. As part of the equipment relocation process, the team at Build by Boyd worked closely with the Oral Care Products team to optimize the production process for greater efficiency.
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Manufacturing
After our Process Development & Validation work, the team at Build by Boyd successfully started commercial manufacturing of the Smileactives® product line. The team blended our initial manufacturing campaigns into the inventory pre-build we had prepared in order to successfully transfer the manufacturing operation without disruption to the product supply. Once the manufacturing operation was at scale, our operations team at Build by Boyd was able to focus on additional process optimization programs to improve material yield and productivity. With a stable operation and improved capabilities, the team at Oral Care Products has been able to increase its focus on innovation and new product development.
Our process improvements included reconfiguring lot printing to reduce label waste, automating the part transition from the filling station to the labeling station to remove operator intervention, and installing a new vibratory bowl to accommodate various cap configurations and new pneumatic cylinders to provide more force to cap parts and greater efficiency.
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Supply Chain Management
Smileactives® is manufactured with a proprietary formulation of various chemicals and liquid media. Our supply chain management team collaborated closely with the Oral Care Products team to successfully transfer material sourcing and supply chain management responsibilities alongside the manufacturing operation. The team at Build by Boyd works closely with the Oral Care Products team to gather demand forecasts and ensure an adequate pipeline of raw materials for ongoing commercial production. Our supply chain management team qualified alternate chemical suppliers and alternate chemical distributors to support Oral Care Products' ongoing business continuity planning.
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Outcomes
Oral Care Products successfully transferred the commercial manufacturing operation for the Smileactives® product line. The new manufacturing operation provided enhanced process efficiency and material yields for Oral Care Products. The transfer of Smileactives® was an important step for Oral Care Products which allowed their team to shift their focus to research and development and product innovation.
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Manufacturing Transfer
Process Optimization
Increased Research & Development
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