The Challenge
A prominent client in the medical device industry approached PrimeTest Automation to address the pressing need to scale up their manufacturing capacity. They were facing limitations with outdated equipment and manual processes that required two operators to handle production. Their goal was to reduce labor by integrating automation, thereby lowering operational costs and increasing efficiency.
Additionally, the client needed to expand their capacity for both an existing SKU and a new product line. The challenge extended beyond capacity and into improving the existing medical packaging process, including upgrading from an old process utilizing a twin track palletizing conveyor system with operators performing manual tasks to a more efficient and cost-effective automated solution built around a dial indexer and Fanuc robots. This would be the client’s first venture into robotic integration, aimed at addressing labor shortages and streamlining production.
Specific Goals and Requirements
Capacity Expansion & Labor Efficiency: To meet the demands of both existing and new SKUs, the client needed to expand capacity while reducing operator involvement. Automation would enable them to decrease labor costs and ensure continuous, uninterrupted production.
Cost-Effective Part Transfer: Their existing twin track palletizing conveyor system was better suited for a hand process, and they needed a more efficient and cost-effective solution. The goal was to integrate a solution that could improve part handling and material transfer.
Quality Control and Part Inspection: The client required a robust part inspection system to ensure accurate part quantities and detect the correct orientation of the Tyvek cover during the packaging process. Quality was paramount, as any defects in packaging could compromise product integrity.
Soft Material Handling: Since the client planned to reduce the number of operators, automated handling of soft materials was essential to maintain the quality and care required for the product.
Part Traceability: Regulatory compliance demanded that each tray be marked with a Lot Number and manufacturing date, including a scannable barcode for traceability throughout the production process.
The Solution
PrimeTest Automation provided a fully customized automation solution that addressed the client’s specific goals and challenges, using advanced technology to ensure precision, efficiency, and cost-effectiveness.
1. Incoming Conveyor for Part Queueing: To streamline the production flow, we designed an incoming conveyor to queue parts before they entered the next stage of production. This ensured that the process ran smoothly without bottlenecks, enabling consistent throughput.
2. Inspection for Tray Full of Parts: A critical component of the solution was the use of a Keyence IV3 inspection system to verify that each tray was correctly filled with parts. This ensured accuracy in the packaging process and minimized the risk of defective products.
3. Individual Dispense of Tyvek Tray Cover: We implemented a stream feeder system for the individual dispensing of Tyvek tray covers. This was crucial for maintaining the integrity of the packaging, as each tray required precise placement of the cover.
4. Inspection of Tyvek Orientation: To ensure correct placement, the Keyence IV3 system was also used to inspect the orientation of the Tyvek tray cover. This guaranteed that the cover was correctly aligned before proceeding to the next stage.
5. 4-Point Inspection of Tyvek Before Sealing: A four-point inspection system was integrated to confirm the presence of the Tyvek cover before heat sealing. This additional layer of quality control ensured that no tray proceeded without being properly sealed... Read Full Post on our Website!
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