Client: A major medical device manufacturer in Europe
Part: Medical Device Housings
Challenge: The medical device manufacturer required high-volume production of housings for their diagnostic equipment. These housings needed to meet strict tolerances and high-quality standards while being produced in large quantities. The challenge was to ensure precision and quality while scaling up production to meet increasing demand.
Solution: HanaV Manufacturing implemented a high-volume machining solution incorporating automated processes, advanced machining equipment, and stringent quality control to meet the client’s requirements.
Technical Achievements:
- Dimensional Tolerances: Achieved tolerances of ±0.01 mm.
- Production Volume: Increased production capacity to 500,000 housings per month.
- Quality Assurance: Maintained a defect rate of less than 0.2%.
- Cost Efficiency: Reduced manufacturing costs by 22% through optimized processes.
Details:
Part Challenge:
The medical device housings required:
- High Precision: Tolerances of ±0.01 mm to ensure proper fit and function within the diagnostic equipment.
- Large Production Volumes: Ability to produce 500,000 housings per month to meet market demand.
- Quality and Consistency: Ensuring high quality and consistency across large production volumes.
Implementation Steps:
Advanced Machining Technologies:
To handle the high volume and precision requirements, HanaV Manufacturing employed:
- Automated CNC Machining: Utilized high-speed CNC machines with automated loading and unloading systems to increase production efficiency.
- Precision Cutting Tools: Selected cutting tools with advanced coatings to handle the machining of materials and maintain precision over extended production runs.
Process Optimization:
Improving production processes was essential for scaling up:
- Lean Manufacturing Techniques: Applied lean principles to optimize workflows, reduce waste, and improve efficiency.
- Automation: Implemented automated material handling and in-line inspection systems to enhance throughput and consistency.
Rigorous Quality Control:
Maintaining quality across high volumes was critical:
- In-Process Monitoring: Integrated real-time monitoring systems to track key machining parameters and ensure dimensional accuracy.
- Automated Inspection: Used automated inspection systems for consistent and accurate measurement of each housing.
- Statistical Process Control (SPC): Employed SPC techniques to analyze production data and ensure consistent quality across batches.
Material and Design Considerations:
Selecting appropriate materials and optimizing designs were crucial:
- Material Selection: Chose high-quality materials to ensure durability and performance of the housings.
- Design for Manufacturability (DFM): Made design modifications to enhance manufacturability and reduce production costs.
Impact on Business:
Dimensional Tolerances: Achieved tolerances of ±0.01 mm, ensuring precise fit and function of the medical device housings, which was critical for maintaining the accuracy and reliability of diagnostic equipment.
Production Volume: Increased production capacity to 500,000 housings per month, enabling the client to meet high market demand and scale operations effectively.
Quality Assurance: Maintained a defect rate of less than 0.2% through rigorous quality control measures, reducing rework and warranty claims while ensuring high standards of quality.
Cost Efficiency: Reduced manufacturing costs by 22% through process optimization and automation, contributing to the client’s competitive pricing and improved profitability.
Conclusion:
HanaV Manufacturing’s high-volume machining solution for medical device housings highlights the effectiveness of advanced technologies and optimized processes in meeting stringent industry requirements. By leveraging automated CNC machining, lean manufacturing principles, and rigorous quality control, HanaV achieved significant improvements in accuracy, production efficiency, and cost management, setting a new benchmark for excellence in the production of medical device components.
