Scaling high-volume medical device assembly to support rapid sales growth
Project snapshot
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Challenge
Meeting high-volume, continuous production demand
A manufacturer and supplier to the medical device industry required a new automated assembly machine to support significant sales growth and increasing order fulfillment demands. Following consultation, AIR identified the need for a system capable of supporting production rates equivalent to 1,000 parts per minute, operating continuously on a 24/7 basis within a cleanroom environment.
Innovation
Multi-lane, linear motor assembly architecture
To meet the demanding throughput and reliability requirements, we developed a highly scalable automation architecture optimized for continuous operation and high part density. The system combines advanced motion control with multi-lane processing to maximize output within a compact footprint.
- Linear motor transport system to precisely manipulate products throughout the assembly process
- Integrated part feeders for separation and orientation of multiple components
- Servo-controlled assembly and test units for consistent, repeatable operations
- Multi-lane technology to process large numbers of components simultaneously
Result
High throughput within a cleanroom compliant system
The automated medical device assembly machine enables the customer’s production line to operate at 50 cycles per minute, with each cycle processing 40 products simultaneously. The system was validated by our engineers up to the IQ phase and fully complies with the requirements of the ISO8 cleanroom environment in which it was installed. The result is that the customer can reliably scale production in line with growing market demand.
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