Automated Assembly Cell for Medical Device Demand

Increased demand projections from their US customer have outgrown the current capability of MiniFab's manufacturing processes in Rowville. To meet this demand, projections indicate that MiniFab must enhance throughput to a maximum 2.5s Cycle Time without adding a burden of an additional shift. However, the existing labour-intensive product assembly process has severely compromised this opportunity, highlighting the need for improved manufacturing cell design and robust automation solutions, including medical device automation.

Consolidating an existing manual 6-step process—encompassing sonic welding, laser identification, component assembly, and vision inspection—into an efficient manufacturing cell design, managed by up to 6 people within a 2.5s cycle time. This process accommodates complex component geometry and ensures proper handling and orientation control, utilizing bulk fed hopper supply and vibratory bowls at optimal cycle rates. Attention is given to preventing product scratching and damage during faster processing and machine handling of sensitive medical diagnostic products through medical device automation. We are focused on sourcing a respected vendor capable of delivering robust automation solutions that meet our cost and timeline requirements. Additionally, batch record control and traceability are maintained to comply with 21CFR and GMP requirements.

The manufacturing engineer served as the project lead for a turnkey automation cell designed to replace several manual processing steps in medical device automation. This involved the development of a detailed User Requirements Specification, as well as the manufacturing planning and design of the six-step process. The project also entailed close vendor engagement and ongoing liaison throughout the project, including trials, testing, and approvals up to the Factory Acceptance Test (FAT). Effective project planning and management were crucial across all milestones, addressing issues, mitigations, and variations to ensure the delivery of robust automation solutions within a strict timeline and budget.

MiniFab introduced a cutting-edge manufacturing cell design that consolidates the previous 6-step labor-intensive activity into a single process. This innovative solution, operated by a single person and requiring a smaller manufacturing footprint, includes features such as vibratory bowl part feed, paired encoded turntables, and 6-axis robots. It also integrates sonic welding, laser ID encoding, and visual quality inspection in under 2.5 seconds. With an advanced HMI providing continuous process control and operator engagement, this robust automation solution enhances medical device automation efficiency.

If you have an operation with similar demand and require expert guidance on manufacturing cell design or medical device automation, reach out to the manufacturing engineer to arrange an initial conversation and kick off the process for robust automation solutions.