Forgotten Soft Costs: The Impact Soft Costs Have on Medical Device Assembly Projects
For manufacturers evaluating new projects in heavily regulated fields, such as medical device assembly, knowing how to calculate ROI for automation...
2 min read
Juan Cardenas
:
Jan 13, 2025 9:00:00 AM
Sub-assembly and Assembly operations can be very labor-intensive or redundant and can create bottlenecks. Identifying these types of tasks is the key to improving productivity and reducing operator workload, allowing them to focus on higher-value tasks.
Repetitive motions tend to cause operator fatigue and mistakes. Even small mistakes can lead to delays, rework, or reduced product quality, making the reliability of assembly operations essential. As production needs grow, manufacturers must balance maintaining accuracy with easing the pressure on their workforce.
Automation in manufacturing offers a practical solution to reduce operator workload, improve production capabilities, and achieve measurable automation ROI. It improves production output, creates safer workplaces, and fosters better ergonomics for operators, thus reducing labor injuries.
Assembly processes often involve repetitive, precise tasks that strain operators over time. Risks include repetitive motion injuries, exposure to hazardous components, and sub-optimal results due to inconsistencies in manual operations/human error. Additionally, in today’s environment, manufacturers are having a difficult time hiring skilled operators, which creates another opportunity for producing defective products. Automated assembly systems address these challenges by reducing physical and cognitive demands on workers.
For example, Intec Automation has designed and built several custom automated lines to process cannula-forming operations like angle bends or tip crimping with precision and repeatability that ensures consistent quality and exact tolerances.
In this example, the next operation tends to be an inspection for quality control followed by capping and packaging operations. A vision system can provide in-line quality inspection, ensuring product standards are consistently met. Vision systems guarantee that every product that leaves the line is flawless, to the exact geometry and specification. Moreover, it can also minimize bottlenecks and keep production running smoothly compared to manual inspection. The same applies to the capping and packaging operations, which can produce repetitive motion injuries as well as mistakes. Automation streamlines processes, significantly reducing downtime. This allows operators to shift their focus to higher-value tasks.
Automated workflows significantly enhance productivity. In the example, described above for the cannula forming machine, Intec Automation designed the machine to perform multiple operations (bending, forming, and crimping) within a single setup by using servo-driven actuators adapted to rapidly changing production parameters, thus ensuring high throughput while saving time, floor space, and resources.
Collaborative technologies further reduce operator workload by sharing tasks between systems and workers. Collaborative robots (Cobots), for example, can handle high-precision steps and fatigue-inducing processes, while operators focus on oversight and higher-value responsibilities. These systems also reduce inefficiencies, further aiding in reducing operating costs while ensuring high throughput. Together, these solutions create a balanced, efficient workflow that benefits both production and operators.
Automation ensures consistent quality by eliminating variability and integrating tools like vision inspection systems to detect defects, thus preventing adding value to a defective part, or shipping a bad product to a customer, as well as reducing waste and enhancing customer satisfaction. If designed properly, automated systems can also scale effortlessly, adapting to changing production volumes or specifications without costly downtime or retooling, making them invaluable for dynamic market demands.
With flexible configurations and streamlined workflows, automation allows manufacturers to maintain operational productivity while focusing resources on strategic goals. It reduces complexity, enabling businesses to pivot quickly when markets shift. By enhancing quality, scalability, and efficiency, automation provides a robust foundation for long-term growth and competitiveness. It also provides a foundation for further automation of other production stages, further enhancing scalability.
At Intec Automation, we act as your trusted assembly integrator, offering tailored systems to meet unique subassembly challenges. By focusing on innovation and adaptability, we ensure our systems align with your unique production requirements. Our expertise in precision tooling and advanced robotics helps manufacturers reduce operator workload while delivering consistent, high-quality results. You can rely on us to transition from manual to automated subassembly and assembly processes.
Ready to transform your assembly operations? Contact us today to discuss how we can tailor automation solutions to meet your unique production needs and help your business thrive.
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