Leveraging Automation At MRPC: Four Successful Integrations

Automation in the manufacturing process provides significant value to the medical device industry by performing repetitive tasks and non-value-adding activities, and by alleviating bottlenecks. Improvements are evident from Safety, Quality, Delivery, and Cost metrics, which include consistency in quality and cleanliness, cycle times, and the cost of goods manufactured (CoGM), but often understated is the value in redeployment of the human element. These redeployments can create bandwidth for a team to train for depth and competence, but also to apply more time to deductive reasoning and creative thinking for continual improvement or problem-solving efforts.

MRPC has been focused on leveraging automation across our three medical device manufacturing facilities for several years. Most opportunities are identified through cross-functional value stream assessments. Once identified, a business case justification will capture the benefits, which also assigns expectations of Overall Equipment Effectiveness (OEE) factors of “Availability, Performance, and Quality.” While multiple applications exist, here are some highlighted examples of successful automation integrations:

Cut to Length (CTL) Automation in Our Butler, WI Location

This system cuts molded parts to a predetermined length. After being sorted and picked from a flex feed system by a SCARA robot, each part is presented to a camera with a telecentric lens where the location that the cut will be made is determined. Then the part is rotated in the presence of a laser beam, which makes the cut.

This fully automated system replaced an operator-tended machine, which improved the OEE for this operation, reduced the risk to cleanliness, and allowed for re-deployment of labor resources, which in turn generated cost savings for the customer. Key system parameters and production performance are monitored in real time through the ERP system.

Vision System Feed and Laser Etching Automation in Our Butler, WI Location

Referencing the diagram below for an automated vision inspection and laser etching system, the feed system (center stage) houses a high-speed SCARA robot that feeds parts to a laser marking bay, where a logo is automatically etched on the product. From there, the parts are distributed to several vision system enclosures by way of six-axis robots, where each part is inspected for visual defects before being tested.

The system in its entirety allowed MRPC to re-deploy several associates to more value-added tasks, which generated labor savings, improved our efficiency, and reduced the risk to cleanliness. Key system parameters and production performance are monitored in real time.

Automated Secondary Operations & Part Handling in Our Largo, FL Location

In our Florida facility, we were able to employ a high-speed industrial robot with a special bi-functional End of Arm Tool (EoAT) in a dedicated, integrated cell, to load and unload a machine performing a post-molded secondary operation.

The results of this installation were labor savings, material savings, and improvements to OEE which are evident through real-time production monitoring

Co-Deployment of CoBot(s) In Our Hudson, NH Location

In this example we demonstrate the flexibility of collaborative robots which are also referred to as cobots. Here we have three work centers that were once tended by human operators: two injection molding machines and a 3D CNC Machining Center. None of these low-volume applications would justify the cost of a dedicated robot, but the investment made sense if they could share one. This cobot has a docking station at each work center, is on wheels, and with a quick change to the EoAT, it is easily relocated to where it is needed.

With the cobot able to perform monotonous, repetitive, machine tending duties, team members have been re-deployed to engage in more value-added activity, and there is the benefit of the reduced CoGM, which generates the ROI and future cost savings. The primary machines that are now tended by the cobot remain as the driver for real time OEE factors.

Continuing Investment in Automation for Medical Device Manufacturing

Moving forward, MRPCs strategy is to expand on the use and deployment of cobots and small to medium-sized modular automation to perform tasks within existing and new production cells. This will enable us to offer our customers more competitive solutions. To support this, and where it makes sense, we will be more proactive in considering robotics and automation integrations up front, to include provisions for capacity expansion and scalability and for new product introductions. Connecting technologies locally will remain a focus along with developing local technical support as to maintain a barrier for security risks.

If you are interested in discussing our automation solutions, and how they may be applied to your medical device or component program, contact us.