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Point of Care Diagnostics Success Story

A major medical diagnostics manufacturer wanted to automate the assembly and die insertion process for their industry-leading point of care product.

wafer placement automated machine with red lights from vision

Challenge

Our client was looking for a high-volume solution to manufacture a point-of-care diagnostic device; the assembly of this device required expertise in placement of a very delicate wafer die into molded plastic parts at high speed.

Approach

The die insertion process required knowledge of high-precision handling and vision inspection of delicate electronic components. Insertion trials showed high reject rates, indicating the need for Pre Automation Solutions. We completed a Proof-of-Principle test to develop a reliable process to insert the die at high speed. The test demonstrated picking die of various sizes from waffle packs and placing to plastic housings without damage.

The insertion process was then refined to fit into a high volume system to fit production requirements. The success of the solution has led to the delivery of several additional systems for the assembly of multiple product variants. Some key processes included in these systems:

  • Die placement to +/- 25 um
  • 1 second cycle
  • Online vision inspections (presence, position, and defects)
  • Corona treatment
  • Vision guided parts feeding
  • Gasket apply
  • Cold staking

We have also reduced the number of process equipment required to assemble this product; this additional improvement was the result of closer collaboration and a strong relationship.

Result

Our client realized a successful launch of high-volume production with improved manufacturing performance features, including:

  • Reduced cycle time by 40%
  • Reduced reject rate significantly from early projections
  • Reduced floorspace by integration of processes into single machine

In addition, a closer relationship means that new product developments benefit from Design for Manufacturing (DFM) and Design for Assembly (DFA) input and improved design processes are implemented in new and existing equipment.