BD pairs lean manufacturing with AI to boost productivity and prepare for healthcare innovation

Since 2023, BD has rolled out its BD Excellence program, applying Toyota Production System principles across supply chain, manufacturing, R&D, and sales teams, while automating processes using AI and robotics. The company's staff of 65,000 conduct about 2,000 kaizens (continuous improvement exercises) each year.

AI vision systems now monitor production lines to identify ergonomic risks and workflow inefficiencies; at one Singapore plant, a kaizen exercise that reversed the grinding wheel direction reduced the scrap rate to zero from about 200 needles discarded each shift. The approach trains employees to be problem-finders, not just problem-solvers.

In its latest quarter, the BD Excellence initiative generated an 8% productivity improvement and record quality and customer service levels. The company completed a spinoff of its life sciences division in February, receiving $4 billion in cash and repositioning itself toward growth in AI sensors, infusion pumps, tissue-regrowth technologies, and pharmacy robotics.