Summary
Re:Build DAPR enhanced the calibration process of a company involved in thermometer production, resulting in increased efficiency and overall improved their manufacturing capabilities.
Location: Confidential
Product: Thermometer Calibration System
Industry: Healthcare
Timeframe: 6 months
Background
The customer approached Re:Build DAPR with a need stemming from the production demand for their primary product, a temporal forehead scanner, due to the COVID-19 pandemic. The forecasted demand for this device exceeded the company’s original production capacity. A critical bottleneck in the production process was identified in the PCB flash/programming and subsequent calibration and test verification stages. The customer’s existing machine, cobbled together over several years, required constant operator intervention and maintenance. Understanding the urgency and the necessity for a more efficient solution, Re:Build DAPR undertook the challenge to redesign and implement a new automated line for this specific process. The goal was to enhance throughput, reduce the need for manual intervention, improve reliability and uptime, and boost overall performance. Our team successfully addressed these challenges, delivering a state-of-the-art solution that not only met but exceeded the customer’s expectations. The implemented system significantly increased production efficiency, allowing the customer to meet the increase demand for their temporal forehead scanners with ease. The success of our solution is evidenced by seamless integration into their production line and the marked improvements in throughput, reliability, and overall operational efficiency.Challenges & Solutions
- Meeting Tight Timeline Constraints. The customer indicated they would not be able to keep up with the COVID-19 demand which would limit their ability to capitalize on sales; as such, they were looking for a completed machine within an aggressive timeframe. Re:Build DAPR project managers and engineers had to incorporate availability and lead times of components when finalizing design decisions in order to meet this customer requirement.
- Optimizing Material Movement with Industrial Conveyance. Efficient movement of materials within the system was crucial for throughput improvement. Standardizing industrial conveyance presented challenges in terms of space utilization and the need for precise coordination between different stations. Re:Build DAPR used software to consider various configurations that minimized floor space while ensuring a smooth and aligned flow of components.
- Designing for Existing Process Parameters. Re:Build DAPR experienced the challenge of enhancing the system while ensuring seamless integration with the existing process environment and parameters. Any deviation could disrupt the entire production workflow, affecting efficiency and reliability so detailed analysis and collaboration with the customer was essential. Our team conducted a thorough review of the current process, identified key parameters, and implemented design modifications that complemented the existing setup.
Successes
The automated implementation and improvements made to the scanners’ calibration stage greatly increased the customer’s throughput from its previous machine. Re:Build DAPR not only automated the previous machine but also included data collection capabilities, allowing for advanced analytics and future improvements to their calibration, accuracy, and quality assurance.