6 Ways Automated Workholding Accelerates Medical Device Machining

Manual clamping and setup for hospital and surgery machinery has advanced to automated workholding for medical machining. In manufacturing, this is a major step forward for efficiency. Machines can achieve higher uptime and greater precision while complying with strict regulatory requirements. A human-machine interface (HMI) is a vital component of these advancements, emphasizing the collaborative nature of the workforce and automated tools. This relationship and technology are impacting the sector in several key ways.

Copious resources have been devoted to establishing traditional medical infrastructure. Machinery requires experts to manipulate finicky clamps, wasting work hours and inviting human error into operations. It also directly contradicts operations attempting to refine and streamline their processes, and this much opportunity for error makes it challenging to validate each step. Alternatively, automated workholding removes these drawbacks, outshining past approaches in the sector.

Digital-based operations aid device control, empowering them with greater flexibility and accuracy. Additionally, it enables teams to better adhere to specific standards, such as ISO 13485, which prioritizes quality management. Automated measuring and setup make manufacturing medical devices more repeatable and consistent.

1. Drastic Reduction in Setup Time

Operators need deep industry knowledge to perform manual workholding. It’s not as repeatable as automated or even hydraulic technologies because of its numerous bolts and clamps. Even with tools like programmable torque wrenches, mistakes may still occur. These oversights are nonnegotiable, especially in medical device manufacturing environments with short cycle times and rapid loading requirements. Manual calibration is too time-consuming.

Automated workholding for medical machining can handle production volumes of all sizes, reducing setup time for each process order. Because of the accessible interfaces in these systems, operators can easily toggle between different production runs. They can improve overall equipment effectiveness by tailoring machinery to each setup.

2. Guaranteed ISO 13485-Level Repeatability

The medical manufacturing landscape requires immense precision with little room for error. Oversights can lead to recalls of expensive and lifesaving products, causing reputation declines and expensive legal ramifications. Therefore, automated workholding to achieve more consistent compliance is one of the most valuable benefits for corporations.

Manual setups introduce too many variables into quality validation. HMI-programmable workholding systems provide visibility into production deviations and variations, so operators can identify issues before they arise and continually refine output to comply with regulations. Additionally, all change controls should be logged in software, streamlining documentation for personnel reviews and required audits.

3. Protection of Delicate and Expensive Materials

While manual clamping can be used with minimal to no damage to the working materials, it’s critical to preserve them as much as possible. Medical devices require hard-to-obtain and expensive components, including polymers and titanium. If technicians make a mistake or are unfamiliar with the best way to handle certain materials, poor handling can lead to cracks and warping, rendering the materials unusable.

These instances are more common than many think. Technicians may overtighten a clamp because they feel it’s more secure or position a material incorrectly because they misunderstood its composition. Automated systems can analyze and configure items in the most optimal position and clamping strength to prevent defects. This maintains high quality control by eliminating distortions and inconsistencies during handling.

It also improves quality control and ISO compliance by potentially increasing the likelihood that the surface finish and assembly meet the requirements for medical devices. Electrified clamping in one prototype minimized surface waviness by 74.1%, and automated hydraulics reduced deformations by 70% compared to traditional clamps.

4. Enhanced Data Logging for Traceability and Process Improvement

Connectivity to sensor-based technologies and software allows manufacturers to obtain workholding data in every machine. Because of the accessibility and precision of digital controls, every action is evidence-based and considerate of the device’s specifications.

They could recognize the make, model, and serial number for each part, creating the most thorough trail of production data for every project. For medical device manufacturing, this is essential for spotting process discovery opportunities and communicating business goals and progress to stakeholders. These values would also be indispensable for predictive maintenance, giving technicians an idea of how long machines remain at peak performance before degradation.

5. Unlocking the Potential of Constant Manufacturing

Some devices used for automated workholding for medical machining have unprecedented efficiency and financial gains, enabling continuous operation. They can be 95% more efficient due to reduced maintenance needs and higher productivity, while saving thousands in operating costs each year.

Automated workholding, when combined with other Industry 5.0 systems, amplifies digital transformation efforts. They are compatible with medical robotics and autonomous vehicles, enabling uninterrupted workflows that can run even when the lights are out. Minimal human intervention is necessary, making it even easier to achieve productivity gains.

Proposing these benefits to potential investors is ideal for sealing the most competitive contracts and meeting the promised lead times.

6. Improved Ergonomics and Operator Focus

The repetitive, tedious, and physically demanding requirements of manual clamping can slowly wear down operators. This strain can lead to injuries in areas like the neck, shoulders, and hands, as manual processes weren’t designed with ergonomics as a priority. Prolonged stress without medical attention can lead to workforce reduction, on-site incidents, and medical bills.

Automated workholding systems remove technicians from situations where they are constantly exposed to strenuous movement, allowing them to preserve their health and well-being. This care is vital, especially as skilled machinists are becoming increasingly scarce and supplies are running short, with 77% of manufacturers struggling to retain top talent. Leaving the challenging alignment and clamping tasks to technology gives workers more variety and value in their workflows. This enables them to dedicate time to higher-value efforts.

The Advent of Automated Workholding for Medical Machining

The position of each fixture of machinery in medical device manufacturing makes or breaks the quality of care. The implementation of touchscreen interfaces for greater visibility or clamping monitors provides better quality control and consistency compared to manual efforts. Keeping humans in the loop ensures the devices maintain compliance and returns on investment, as their insights will continually refine machinery’s advantages for the foreseeable future.

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Emily Newton is a technology and industrial journalist and the editor-in-chief of Revolutionized. She manages the site’s publishing schedule, SEO optimization, and content strategy. Newton enjoys writing and researching articles about how technology is changing every industry. When she isn’t working, Newton enjoys playing video games or curling up with a good book.