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Inspection Roundtable

A medico client used an outdated and insufficient machine for assembling a new type of medical device. The existing assembly machine produced a very limited output and generated a number of quality deficiencies that all together made the client’s production highly inefficient. A more automated process with precision quality assurance was needed.

Allesoe Custom Machinery designed a custom assembly machine that fully automated the production process with complete inspection control, and consequently the client’s needed output levels and product quality was reached, thereby achieving the necessary output to fulfil demand while reducing production costs.

In collaboration with constructors from Allesoe, the client’s project manager outlined the essential requirements for the assembly process, and specified critical areas of quality control. From here on Allesoe’s constructors and technicians took over the assignment and designed a solution for the client’s production.

The Solution

Allesøe developed and manufactured a fully automated roundtable with 2×6 stations. The client had specified a production output of 90 units per. minute. The final solution was, however, able to complete and inspect more than 100 units per. minute. The assembly process entailed:

  1. Feeding of various components
  2. Insertion and gluing of components with subsequent UV curing
  3. Test, including flow and destructive tests and subsequent lubrication with silicone
  4. Feeding and attachment of the outer sheaths
  5. Vision of the finished assembled items
  6. Extraction of good subjects and disposal of any defective units

The assembly unit was developed in close cooperation with the client, who contributed with knowhow, and a number of critical well-functioning components from the previous machine were incorporated into the new unit.

It was a requirement that the roundtable could assemble three different sizes of subcomponents, and in this regard the client participated with experience from previous production settings to create the most appropriate and user-friendly solution.

The roundtable solution is more compact than an assembly line, but it also presents the production with a risk of complete breakdown, as the stations typically are interdependent.

“We designed this particular unit such that each station can be disconnected for maintenance and repairs without affecting the remaining stations and thereby we managed to eliminate the interdependency between stations” says CEO Lars Allesøe.

In this manner, overall equipment efficiency is improved, as it is still possible to operate at 50% capacity even during unexpected repairs and planned maintenance activities.

ROI

The roundtable unit proved profitable after only a short time as the client was able to respond to the high market demand, but there were other gains from the replacement of the old assembly machine.

“Many operators are quite satisfied with the older machines that they use as they have become accustomed to living with the machinery’s flaws and shortcomings, therefore, many companies are reluctant to automate their production further.

However, investments in new machinery often have a short repayment rate simply by maintaining a stable production and quality assurance without losing machine hours and having high maintenance costs on old and outdated machinery” concludes Lars Allesøe.