ICU Hospital Bed
Challenges:
- Make a significant reduction in assembly steps
- Labor cost reduction is important
Achievements:
- Reduced part count 42%
- Reduced number of operations 43%
- Reduced labor cost 42%
- Reduced complexity of the product design and improved quality
- Reduced Cost of Quality 34%
- Reduced assembly time 44%
- Reduced fixture and tool usage 34%
- Considered a success by both engineering and manufacturing
Medical Device Front Panel Assembly
Challenges:
- Complex assembly with special adhesively-bonded section
- Cost and quality issues with poor bonding and part failure at fastener locations
- High queue times and excess work in process inventory
Achievements:
- Reduced part count 80%
- Improved throughput 59%
- Total annual savings: $300,000
- Reduced complexity of the product design and improved quality
- Reduce number of operations 75%
- Reduced total product cost 74%
- Return on Investment in less than 6 months
- Eliminated special bonding fixture
- Eliminated part failure issues with elimination of separate fasteners
Medical Device – Positive Pressure Ventilator
Challenges:
- Electro-mechanical product with mechanical susceptibilities
- Micro-processor based, servo controlled blower assemblies
- Control valves and patient diagnostic display
Achievements:
- Reduced part count 64%
- Reduced total product cost 68%
- Reduce number of operations 76%
- Reduce assembly time 68%
Squeeze Bag Resuscitator, Respironics, Inc.
Challenges:
- Improve Quality & performance with added & improved features
- Ease assembly operations & reduce manufacturing costs
- Produce a multi-market family of products
- Complex, difficult assembly partially assembled offshore
Achievements:
- Six Patents & SPE International Consumer Product Of The Year Award
- Reduced complexity of the product design and improved quality
- Reduced part count 66%
- Reduce number of operations 81%
- Reduced assembly time 84%
- Reduced total product cost 74%
- Reduced development time (TTM) 50%
- Returned all assembly operations to U.S.A.
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