Each test kit has hundreds of quality parameters that need to be tracked during production. Job 1 was bringing this data—captured in many different legacy systems under varied data schema— into a single, clean, dynamic, and real-time database. Marlabs teams used a range of AI-enhanced ETL, mapping, and integration tools to extract and organize data from all manufacturing facilities and lines and bring it into a single central database. Then, we built an automated analysis tool that provides dynamic and flexible visualization, rapid drilldowns into specific components, and other critical analyses. Now our client has a near-real-time way to track individual kit quality, find and address manufacturing issues within a batch, and provide critical quality assurance reports to regulators.

A tsunami of demand had overwhelmed the company’s ability to allocate materials, prioritize orders, and manage inventory, turning “just in time” to “just before disaster.” So we quickly put into place an automated, analytics-rich, and scalable planning system that can prioritize orders, route raw materials, create inventory plans, and optimize production schedules. To manage today’s extreme supply fluctuations, the solution performs extensive scenario planning that allow it to assess demands and risks for each item on the Bill of Materials and dynamically reallocate raw materials as needed.

In the US, the Food and Drug Administration (FDA) must review and sign off on each test kit batch before it can be shipped. When we arrived on the scene, our client had been manually collecting and formatting critical quality and manufacturing data for these submissions. We rapidly built a digitized, end-to-end automated process that has cut report generation and submission time down from several hours to under a minute. Now, the FDA gets sent accurate, correctly formatted information in near-real time, with zero manual effort.