“Robots Streamline Assembly and Testing in Medical Device Production”

Robots Streamline Assembly and Testing in Medical Device Production

Understanding Automation in Medical Device Manufacturing

Automation in medical device manufacturing refers to the use of technology, particularly robotics, to streamline processes such as assembly and testing. This reduces human error and increases efficiency in producing critical devices. For example, a medical device manufacturer might employ robots for tasks like assembling components of a blood-flow measuring device.

Tessy Automation recently tackled a project for a medical device that had been in use for over 20 years. Their goal was to modernize the assembly process to enhance performance and user-friendliness, thereby improving outcomes for doctors and patients alike.

Key Components of Automated Assembly Systems

An automated assembly system consists of various components, including robots, conveyors, and control systems. For instance, Tessy Automation’s assembly line spans approximately 31 feet and incorporates various technologies such as precision link conveyors and multiple SCARA robots. Each of these components plays a vital role in ensuring the seamless flow of assembly operations.

Using robots like the Epson T3, which has built-in controllers for simplified installation, enables fast and efficient operations. The choice of components directly influences production rates and overall machinery efficiency.

Step-by-Step Lifecycle of Automation Implementation

Implementing an automated assembly system involves several key steps:

1. Assessment of Needs: First, manufacturers assess their production demands and identify pain points in the current system.

2. Design and Planning: Next, they design the system based on these needs, incorporating components like SCARA robots and conveyor systems.

3. Installation: The system is installed and integrated into existing workflows. For example, Tessy Automation leveraged CAD files to create a visual representation of each assembly station, making it easier for staff to understand the new setup.

4. Testing and Quality Control: After installation, thorough testing is conducted to ensure all components function as intended, aided by in-line quality tests for torque and flow in the medical device created.

5. Training and Maintenance: Finally, staff are trained on the new system, and maintenance routines are established to sustain performance over time.

Practical Example: Case Study of a Medical Device Manufacturer

Tessy Automation provides a noteworthy case study in automated assembly. The company designed a fully automated system capable of producing up to 17 million medical devices annually. Their approach involved a combination of SCARA robots for pick-and-place tasks and vibratory bowl feeders for parts orientation.

This strategic integration allowed them to not only enhance production capacity but also ensure flawless quality through real-time monitoring systems that aid in quick troubleshooting.

Common Pitfalls and How to Avoid Them

A frequent challenge in automation is underestimating the complexity of integration. Poorly executed installations can lead to significant downtime. To avoid this, clear planning is crucial. For example, ensuring that the conveyor systems and robots have compatible specifications can prevent bottlenecking.

Another common issue is the need for ongoing maintenance. Without regular checks, systems can become inefficient. Manufacturers should establish a routine maintenance schedule to keep operations running smoothly.

Metrics for Success

Measuring success in an automated assembly system can be accomplished through several key metrics:

• Production Rate: Monitor devices produced per hour. Tessy Automation’s line achieves an impressive production rate of 17 million devices annually.

• Quality Assurance Metrics: Use metrics such as defect rates from quality tests to evaluate the reliability of the output.

• Operational Downtime: Track unplanned downtime to identify and address maintenance issues promptly.

These metrics provide insights into the efficiency and effectiveness of the automation process, allowing for data-driven decision-making.

Variations and Alternatives in Automation

There are various types of robots and automation systems suited for different manufacturing needs. SCARA robots, for instance, excel in tasks requiring precision and speed, making them ideal for assembly lines in the medical device sector. Alternatively, six-axis robots offer greater flexibility for more complex tasks.

Choosing the right type involves weighing factors such as required precision, payload capacities, and cost. For example, the compact LS6-B robots chosen by Tessy Automation are both cost-effective and efficient, fitting their specific manufacturing needs without unnecessary expenditure.