Diagnostic manufacturing tools to accelerate production ramp-up
Project snapshot
Client:
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Challenge
Replicate an in-house manufacturing tool to increase production
A medical device diagnostic manufacturer needed to rapidly replicate an in-house designed manufacturing tool to support a production ramp-up. The tool included multiple control systems and needed to be an exact copy, but documentation was limited. Customer engineers were focused on new product development and tool commissioning, leaving little capacity to support replication.
Innovation
Rapid tool replication and documentation capture
We partnered with the customer to replicate the manufacturing tool while reducing engineering burden and accelerating ramp-up.
Our approach focused on:
- Identifying gaps in existing documentation and capturing unspoken design intent.
- Working alongside customer engineers to formalize a complete documentation package during the build, enabling future repeatability and reducing dependency on tribal knowledge.
- Validating and refining the bill of materials, identifying redundant components and correcting errors to reduce system cost and complexity. Taking ownership of tool commissioning and production ramp-up ensuring the replicated system met performance and alignment requirements without additional burden on the customer’s engineering team.
- Developing tooling and software to support efficient system testing and alignment.
Result
Faster ramp-up with reduced cost and engineering effort
The replicated tool shortened system debug and alignment time from eight weeks to three, enabling faster production ramp-up with reduced engineering effort.
In addition to speed, the effort delivered:
- A more complete and structured documentation package for future builds.
- Reduced system cost through bill-of-material optimization.
- Lower ongoing engineering burden for the customer’s internal team.
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