Michael Parrilla explains how this technology manufacturer is improving women’s health screenings and saving lives.

Fact: Each year, more than 225,000 women are diagnosed with breast cancer in the US, and approximately 50,000 die from it. Fact: 300,000 individuals suffer hip fractures in the US each year. Approximately 20% of women who fracture a hip die, and 50% never regain their independence. Although these statistics are startling, studies show that when breast cancer is detected and treated in its earliest stages, the five-year survival rate is 98%, and with proper treatment, the life-altering effects of osteoporosis can be minimized. Hologic is here to help.

Bedford, Mass.-based Hologic is improving women’s health by designing and manufacturing advanced digital imaging equipment that allows physicians to more accurately diagnose breast cancer and osteoporosis.

Michael Parrilla

Hologic’s primary digital breast-imaging technology, Selenia, incorporates proprietary direct-conversion amorphous selenium detectors, which convert X-ray energy into an electrical charge without the use of light for a sharp, clear image. SecurView diagnostic and technologist work stations improve communication in the imaging suite and allow radiologists and technicians to view images in multiple configurations. In addition, Hologic developed Selenia breast tomosynthesis, which creates a 3D image using a series of flat images at multiple angles. Other products include R2 computer aided detection; ImageChecker, a family of CAD products; as well as image storage devices such as DigitalNow and MIMS-plus.

Hologics’s skeletal health division designs and manufactures the Fluoroscan InSight mini C-arm X-ray system for minimally invasive surgical procedures on extremities, as well as low-dose, in-office imaging procedures. Hologic’s Opera extremity MRI (only available in the US) and C-Scan extremity MRI further serve the orthopedic and rheumatology imaging markets.

Leaps and bounds
According to Michael Parrilla, vice president of manufacturing and operations at Hologic, when he joined the corporation four and a half years ago, revenues were approximately $180 million. Today, the company is nearing the $700 million mark and growing. He attributes that growth to more rapid adoption of digital mammography and the success of the company’s Selenia system.

In 2000, Hologic acquired Lorad, a company specializing in film screen mammography and further strengthened its position with last year’s purchase of R2, Suros, and AEG.

California-based R2 designs and manufactures computer-aided mammography equipment. “We acquired R2 because we incorporate CAD in about 80% of our digital mammography systems,” Parrilla said. As a result of the acquisition, R2 moved its engineering team to another facility in California and transferred its manufacturing arm to Hologic’s Bedford, Mass. plant.

Indianapolis-based Suros designs and manufactures breast biopsy devices. The Suros ATEC line of biopsy hand pieces, markers, and peripheral devices are a perfect fit with Hologic’s biopsy guidance systems, such as the Multicare Platinum stereotactic system.

According to Parrilla, the acquisition of AEG, a German company that produces selenium and organic coatings for medical and non-medical applications, was strategically important. AEG’s medical-grade selenium coating products are integral elements in Hologic’s mammography equipment. “AEG was one of our suppliers, and having it under our umbrella will enable us to not only improve the digital panels currently in use, but also develop new ones,” he said.

Hologic recently announced a definitive merger agreement with Cytyc, the world leader in automated pap smear technologies and gynecologic interventional devices.

Operational improvements
Hologic’s Bedford location is home to its skeletal health division, where its bone densitometry equipment is manufactured. Two facilities in Danbury, Conn. manufacture mammography equipment, and the Newark, Del. facility is focused on digital panel technology.

To improve production at all three facilities, Hologic is blending Six Sigma and lean manufacturing methodologies. “The quicker we get our products to market, the better, so we’re constantly improving our processes to reduce cycle times,” said Parrilla, who taught lean manufacturing classes for several years. “Six Sigma will be valuable in the Delaware plant, which is a very process-oriented manufacturing environment.”

Kaizen events take place on the manufacturing floor regularly. Teams review how each product is built, what improvements could be made to the manufacturing process, how to minimize the movement of people and parts, and how to keep minimal parts inventory. In addition, Hologic has hired the Association for Operations Management (APICS) to train its employees on modern manufacturing techniques.

The company combines lessons learned from lean/Six Sigma with feedback from field engineers and customers to improve processes and final products. “Feedback from our customers is infinitely valuable. We review their input on a weekly basis, and when we find an area that could use improvement, we act on it immediately,” Parrilla said.

In addition to adopting continuous improvement manufacturing methodologies, Hologic successfully implemented Oracle. The process began in 2003, and AEG is the only location yet to transition. “We are standardizing our business processes and procedures with one business system that ties together all of our financials. I can look at any one of my plants and see how we are performing against certain metrics,” Parrilla said.

Business processes and technology aside, Parrilla said the driving force behind the company is its people. “I have been in manufacturing for 32 years, and this is by far the best corporation I’ve been with and the best group of individuals I’ve worked with,” he said.