Introduction:

In the realm of medical device manufacturing, ensuring the safety and quality of products is paramount.  The reliance on manual inspection methods posed several challenges for our client. Manual inspection methods were labor-intensive, requiring significant human resources and time investment. Despite the best efforts of skilled inspectors, manual methods remained inherently prone to human error, leading to potential oversight of critical defects. The manual inspection process had limitations in its ability to detect subtle defects, raising concerns about product integrity and patient safety. As demand for urinary catheters grew, the inefficiency of manual inspection processes became increasingly evident, hindering the company’s ability to scale production to meet market demands.

Recognizing the need for a more reliable, efficient, and accurate inspection solution, our client sought to revolutionize their inspection processes through automation.

The Solution

Catalyx developed a custom-built Catheter inspection system using an automated material handling system paired with Catalyx SmartFactory Machine Vision. The system can inspect a wide range of different catheters. All parameters for cut patterns, length, inspection tools, and method are customizable through the Catalyx SmartFactory Software Suite Technology used in the system.

Key Results:

Improved Efficiency:

Cycle time reduced from 5 to 12 minutes to a remarkable 5-minute cycle time. Changeover time slashed to less than 2 minutes, enhancing operational agility. System setup time minimized to under 5 minutes, facilitating swift transitions between production runs.

Enhanced Accuracy:

Automated inspection system delivers consistent and reliable results, virtually eliminating the risk of human error. Comprehensive defect detection ensures uncompromised product quality and patient safety.

Customizable Inspection Parameters:

Versatile system accommodates catheters up to 139 cm in length, catering to diverse production needs. Modifiable inspection tools and methods provide flexibility and customization options.

Compact Form Factor:

Catalyx’s solution offer a footprint savings of 200%, optimizing floor space utilization without compromising functionality or performance.

Robust and Compliant Tracking:

Comprehensive tracking capabilities ensure robust traceability throughout the manufacturing process, meeting regulatory standards and bolstering quality assurance efforts.