Adaptive manufacturing transforms the medical device assembly

In the ever-evolving landscape of medical device assembly, innovation knows no boundaries. Leaders in medical device assembly are pioneering solutions with unprecedented capabilities to produce multiple product types, facilitating small-batch flexibility without compromising on productivity. This represents a significant shift towards the utilisation of machines that can adapt, acknowledged as adaptive machines, and excel in performance with dynamic changes in manufacturing processes and consumer demands. As per recent reports and the spread of ‘Atmanirbhar Bharat’, the government and regulators are also pushing advanced technologies to tighten up and standardise the manufacturing and distribution of pharmaceutical products. Digitisation and advanced automation have opened the door to protect consumer safety and avoid diversion, theft, and counterfeiting. The ongoing digital revolution is focused on creating seamless connectivity between machines, processes, and individuals within and beyond manufacturing facilities. The primary objective is to focus on quality control, productivity, reduced wastage, and profit from the power of advanced data analytics. By implementing solutions for advanced automation, Industry 4.0, mass customisation and sustainable manufacturing, pharma companies can drive better operations, increase efficiencies, improve product quality, and fulfill regulatory compliances. The adaptive machines make all of these possible with possibility of easy change over during process, higher performance with reducing the machine footprint and making ready for any unforeseen demands. These machines don’t just solve challenges; they redefine what’s possible, steering in a new era of problem-solving that goes far beyond conventional methods.

Adaptivity in the medical device assembly line

Imagine a production line producing small batches of medical devices and procedural kits with all the adaptivity features and maintaining same level of efficiency as high-volume production. Adaptive manufacturing possesses some of the below features as an add on help to your regular production work.

·     Easy changeovers on the fly: Traditionally, shifting from one product to another on an assembly line was like preparing a new recipe or outfit. But here, imagine a world where changeovers happen in the blink of an eye – without any human intervention. Materials glide on independently controlled shuttles, adapting to the new product or packaging seamlessly. No retooling, no adjustments for size or shape, and not even a change in recipes or parameters. It’s like a magician’s quick-change act, only this magic is real.

·    Easy profitable personalisation: Picture this – different materials, each with its unique characteristics, flowing together like dancers merging on a dance floor. These materials effortlessly combine on the fly to create small batches of medical devices or custom kits and packs, all while maintaining the rapid pace of full production speed.

This adaptivity in medical device assembly is not just a technological advancement; it’s a show-stopping innovation that redefines what is possible in manufacturing. It’s the future of medical device production, and it is as engaging as it is transformative.

Adaptive transformation

With the market developing to grab the finest of technologies, manufacturers are embracing innovative and sustainable solutions to ensure seamless production. Traditional manufacturing processes often face challenges when it comes to making even minor product adjustments, causing disruptions and downtime. However, the dawn of adaptive manufacturing technology promises to revolutionise this industry by allowing real-time, hassle-free product modifications without interrupting the regular workflow. In the pharma industry, quality assurance is paramount. Without it, companies cannot adhere to the product’s necessary quality and safety standards. Many times, product quality suffers because of machine downtime. Innovative products from B&R portfolio like ACOPOStrak, Supertrak and ACOPOS 6D system provides many distinctive movement possibilities to enhance production processes. For example, they enable the use of parallel production stations to distribute workloads efficiently and seamlessly merge product flows to create custom kits and packs on-the-fly, all while maintaining full production speed. Also, a prime example of controlled motion is the use of anti-sloshing feature; the movement parameters can be adjusted depending on the fluid type, container dimensions, and fill height. The anti-sloshing feature makes it possible to use a shorter container since the liquid or powder does not reach up as high in the container during movement. Reducing container size helps reduce packaging material. Reducing packaging material benefits the environment and lowers the total cost of production. Moreover, the use of robots creates big advantages for medical device assembly in terms of both production efficiency and total cost of ownership. With machine-centric robotics, B&R has taken another big step towards higher productivity and efficiency. There’s no longer a need for separate hardware and separate communication. The machine doesn’t need to wait for the robot, nor does the robot need to wait for the machine. Simultaneous movements in perfect synchronisation with zero waiting time generate higher productivity and take OEE of the manufacturing process to new heights.