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 They were facing limitations with outdated equipment and manual processes that required two operators to handle production.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

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. Heat Sealing and Tray Marking: After the trays were heat-sealed, they were marked using a Videojet model 1880 with the manufacturing date and Lot Number, ensuring traceability for each individual product.

7. Barcode Printing and Scanning: A scannable barcode was printed on each tray to confirm readability and compliance with industry traceability standards. This allowed for quick and easy tracking throughout the manufacturing and supply chain.
 

The Outcome

 

The client’s decision to work with PrimeTest Automation resulted in a fully automated, highly efficient manufacturing process that significantly expanded capacity while reducing labor costs. The use of robotics for part handling, along with advanced inspection systems, improved the quality and consistency of the client’s medical packaging.

By utilizing a dial indexer, Fanuc SR3 Scara robots, and integrating the IV3 inspection systems, the client was able to meet their increased production demands while maintaining product quality. The automated system also provided full traceability, from Lot Number marking to barcode scanning, ensuring compliance with industry regulations.

The client’s first robotic integration proved to be a resounding success, further enhancing productivity and reducing operator dependency. PrimeTest Automation’s custom solution allowed the client to meet their goals while positioning themselves for future growth.

At PrimeTest Automation, we specialize in delivering tailored automation solutions that drive efficiency, improve quality, and reduce costs. Contact us today to learn how we can help you transform your manufacturing process.