Fit for Purpose
Inside the quality control labs in Vietnam
16 December 2022
Category:
Sustainable manufacturing and qualityFighting malaria starts with the quality of a solution
One way we measure how successful our contribution to the fight against malaria is through the quality. When we set out developing PermaNet long lasting insecticidal nets (LLINs) we wanted to design and produce them to be "fit for purpose". In other words, LLINs should meet the needs of users and deliver long-term value for our customers.
Since 2017, our customers have reported zero quality assurance incidents — underscoring the reliability and consistency of our manufacturing processes in delivering LLINs that protect lives.
While quality management may seem like a simple, step-by-step process, Benoît Florin, our Operations Director emphasizes that “There are many diverse and complex processes with a lot of parameters involved in making LLINs that can impact the performance of the nets. Therefore, the quality of each step in the chemical textile manufacturing processes matters greatly to the end product.”
From process to product, every step protects lives
If LLINs do not meet certain specifications, they are not effective at preventing malaria. Defects can take many forms, each with real consequences for performance. A net that falls short of standard dimensions, too small in height or width, is more vulnerable to tension and tearing. An imbalance in the chemical composition can compromise its insecticidal effect. Ultimately, delivering a net that performs as intended relies on one thing: a robust and well-executed quality management system.
In-house testing for greater control
We focus on strengthening quality management at the manufacturing level through a process of ongoing review and refinement. To enable full traceability, every detail is recorded from raw materials through to production lines and sub-batches of distributed nets.
Vestergaard is one of the few LLIN manufacturers with in-house laboratory facilities dedicated to checking chemical content — a vital process carried out at our quality control lab in Vietnam.
“Over 30 quality controls are in place during the manufacturing, labelling, and packaging of our bed nets so that we can detect a failure at the earliest stage,” explains Benoît. “These controls allow us to identify, isolate, and correct the issue immediately. We know when and where an issue has occurred and ensure that there is no impact on the quality and delivery of the commercial order. Every manufacturer knows that issues can arise during production, but when people’s lives are on the line, then you have to adopt a zero-tolerance policy to quality assurance.”
“Having quality control laboratories at our production workshops enables us to correlate the quality of the products with the quality of the processes,” he adds. “We rely on a day-to-day collaboration between the production and quality departments to support the implementation and improvement of the quality management systems.”
In addition to dupro (during production) checks, ongoing testing of net bioefficacy provides a critical feedback loop to both quality control and quality assurance teams. Post-market surveillance activities are also invaluable to evaluate the performance of used nets in real-world conditions.
Motivated to deliver excellence
“The spirit of the team in Vietnam is truly inspiring: our staff are extremely hard-working, highly skilled, happy to collaborate and eager to improve,” said Benoît. “As a manager, I find it especially beneficial to empower my team as much as possible while having the necessary routines in place. This usually means providing a path for growth to each member of the team.”
The laboratory team consistently shows flexibility and commitment. We also have a mobily quality unit, the Vestergaard Acceptance Testing Inspection (ATI) team, which travels between all sites to conduct inspections. They never miss a visit, whether there is extreme heat or heavy monsoon rain, the ATI team ensures that orders are released and shipped on time.
Evolving quality in the field
External engagement is another essential component. Regulatory authorities and donors have strengthened pre-shipment inspection, sampling and testing of LLINs, as well as audits of manufacturers and this plays a critical role in raising quality standards across the LLIN sector. Their involvement in inspections, audits, and performance reviews strengthens transparency and accountability. As part of this process, independent health regulators periodically conduct site visits focused on manufacturing and quality systems. These engagements not only help us verify that our quality tools and processes are in place but also create opportunities for constructive dialogue between industry and oversight bodies—helping shape a shared understanding of what strong quality management looks like in the field.