Becton Dickinson - Plymouth
Company Background
Becton Dickinson, a leading manufacturer of vacuumed containers for medical use, operates a large facility in Plymouth. Over the years, Marley Comms has developed a strong working relationship with Becton Dickinson, beginning in 2018 with the installation of a guest Wi-Fi network in their canteen areas. Following the success of that initial project, Marley Comms was entrusted with a subsequent CCTV installation and, most recently, the implementation of a crucial fibre optic network upgrade.
Project Overview
The latest project, Phase 1 of a larger fibre optic installation, was focused on enhancing the communication infrastructure between the MDFs and IDFs across two key buildings within the Becton Dickinson facility. The project involved installing two diverse fibre links between the MDFs of Building 1 and Building 2, using 48-core armoured OS2 fibres. Additionally, 12-core fibre links were installed between the MDF and IDFs within each building. The installation was designed with future expansions in mind, ensuring that the infrastructure could accommodate additional fibres in Phase 2.
Objectives
The primary objective was to replace the ageing multimode fibre network, which was a mixture of OM1, OM2, OM3, and OM4 fibres dating back to the 1990s. The legacy system was struggling to meet the increasing bandwidth demands of modern operations. The newly installed OS2 fibre network, capable of supporting speeds up to 100 Gbps, was chosen to future-proof the facility's communication infrastructure and significantly enhance data transfer between critical operational areas.
Challenges
Several challenges arose during the project. The first was the necessity to avoid interrupting production, as Becton Dickinson's operations involve clean room environments where minimal disruption is critical. Additionally, ensuring that the fibre runs were continuous with no splices was essential for maintaining signal integrity over distances averaging 200 to 300 metres, with some runs extending up to 500 metres. The 48-core SWA armoured fibres were particularly challenging to install due to their weight and the complexity of the pulls.
Solution
To address these challenges, Marley Comms devised a solution that minimised disruption to production by avoiding cable runs through clean room areas. Instead, the team opted to install the fibre cables on the flat roof of the factory, where a dedicated cable tray was erected specifically for this purpose. This approach not only saved time on the fibre pulls, as the runs were straighter and more direct, but also significantly reduced the risk of contamination or disruption within the factory. The cables were then routed into the buildings near the MDFs and IDFs for termination.
Process
The project commenced with the delivery of materials directly to the site, allowing the us to focus first on erecting the cable tray on the roof. Once the tray was in place, the fibre cables were laid out, with excess cable left at entry points to the building for final connections. The most challenging part of the installation was the two 48-core SWA armoured fibre runs between the MDFs in the two buildings, each approximately 500 metres in length. These runs required significant manpower to complete without any breaks. The cables were routed through ducts between the buildings, and once inside, they were run to the data cabinets using scissor lifts and boom lifts, ensuring that all work remained in the warehouse areas and did not disrupt manufacturing. All engineers involved were IPAF trained and certified to operate Mobile Elevated Work Platforms (MEWPs).
Results
Upon completion, all data links were thoroughly tested using a DSX fibre tester, and the results were provided to the customer for their records. Although the customer plans to activate the network only after Phase 2 is completed, the installation has already been deemed a success.
Client Feedback
Becton Dickinson expressed satisfaction with the installation, particularly highlighting the professionalism, communication, and efficiency of the Marley Comms engineers. Additionally, Becton Dickinson noted that Marley Comms was the most price-competitive bidder among the three companies that tendered for the project.
Conclusion
The successful completion of Phase 1 of the OS2 fibre installation at Becton Dickinson’s Plymouth facility represents a significant upgrade to the company’s communication infrastructure. By overcoming the challenges associated with running fibre cables in a production-sensitive environment, Marley Comms delivered a solution that met the client’s needs for reliability, scalability, and minimal disruption. The project's success further strengthens the relationship between Becton Dickinson and Marley Comms, setting the stage for continued collaboration in Phase 2 and beyond.