A lesson in compatible innovation

The brief

Sanofi-Aventis, the world’s third-largest pharmaceutical group, had just developed a metered-dose, dry powder inhaler, but increasing focus on patient compliance, especially in the US, demanded that a dose counter be added. So they engaged us to conceive, design and implement it.

What we did

Working with the Sanofi-Aventis international supply chain in Europe, Scandinavia and the US, we began ethnographic research with asthma experts, nurses and sufferers alike. This allowed us to define robust user and product requirements that were later endorsed by the FDA when it mirrored their findings in its published specifications. The next challenge was to design a counter mechanism that would not change the existing device’s performance whilst also being compatible with the existing manufacturing plant and automated assembly machinery. On top of all this this, we also needed to bypass a particularly mature intellectual property field. Our solution was to design a selection of design elements that could sidestep existing patents. We then produced concept models, machined and cast prototypes and aluminium tools for testing. These components were then approved using our CMM (co-ordinate measuring machine) and CGI (Capture Geometry Inside) processes. The mechanism was then further tested even further against extreme combinations of tolerance, material properties and temperature.

Result

Through qualitative research, inventive mechanisms, precision engineering and prototype verification, we were able to provide Sanofi-Aventis with a patented counter mechanism that is now an integral part of the Sanofi-Aventis MDPI.
Since this project in 2001, PDD has continued to provide innovation and support on a number of Sanofi-Aventis programmes within its respiratory technology and drug delivery activities.

Client's Comments

"PDD’s continued partnership and support has helped Sanofi-Aventis to implement an innovative design solution that fits our current manufacturing plant and is sympathetic to our supplier’s 6 Sigma requirements."

Dave Shadwell, Sanofi-Aventis