Automation & AI: Shaping High-Mix/Low-Volume Manufacturing

The medical manufacturing industry is defined by constant innovation and high-level competition. As quality and delivery standards rise year after year, high-mix/low-volume manufacturers must adopt new technologies to stay ahead of the curve. Implementing a strategic automation strategy enables suppliers to improve lead times and increase quality, all while becoming more cost competitive.  Rather than replacing skilled labor, automation has become a tool for growth. Operators are no longer stuck in repetitive tasks, but instead work on higher-value, higher-skilled operations that improve long-term competitiveness.        Alongside automation, the use of Artificial Intelligence (AI) further improves processing speed and error reduction. AI-driven models enhance programming efficiency and accuracy, maintain higher standards of quality, and support informed decision-making. Incorporating AI into part rendition decreases programming time, allowing programmers to focus more on quality assurance and optimization. Using a large database of tooling and machine capabilities, AI informs engineers of optimal decision-making to reduce human error.

Automation  

Automation is no longer an option; it is a necessity in order to become an industry leader in high-mix/low-volume manufacturing. Arcamed has utilized technology to successfully maintain their industry-leading lead time and build a world-class Quality system throughout consistent organizational growth. Since its adoption, automation has made massive strides for cost reduction, lead time stability, and efficiency.        But what automation was introduced, and how did it add value? Arcamed currently utilizes four robots:      

1. Ra2-Del2: Tends a radel caddy lid CNC mill by loading/unloading material and transferring lids to be laser etched with a lot number. This has resulted in a work cell that can run up to 40 parts per load, allowing for up to 15 hours of unmanned run time.  
2. Eva: Tends a CNC mill that produces the first operation of machined caddies. This has resulted in a work cell that can run up to 28 parts per load and run for 60 hours unattended.   
3. Wall-E: Tends a CNC mill that is responsible for caddy material preparation. This has resulted in a work cell that can run up to 60 parts unattended for 2 hours.   
4. Bender: Tends a press brake to automate the production of single bend brackets and stock component latches. This has resulted in a work cell that can run up to 1400 parts for 11 hours unattended.       Automation has not taken away skilled labor from the workforce – but has transformed it. Employees previously in repetitive cycle-to-cycle jobs now work in more complex environments that improve technical skills and long-term competitiveness. Operators previously tasked with tending to a machine and cycling parts can now develop into programming the robots, innovating processes, and manufacturing complex parts.

Cloud NC  

In 2024, Arcamed implemented Cloud NC to optimize programming efficiency. Cloud NC is an AI model used to enhance programming efficiency and maximize output. Using CAM Assist, engineers will render the initial part, which is then analyzed by Cloud NC for machineability. If any errors or inefficiencies are found, the model will provide solutions to optimize program quality.  The engineer will then focus on optimizing and validating the program prior to being sent to manufacturing. With its large database of tooling and machine knowledge, Cloud NC can even assign parts to the appropriate equipment with the most optimal tooling to optimize production.       The integration of Cloud NC has elevated Arcamed’s programming efficiency to industry-leading standards. Programming can result in a production bottleneck, with slower processing rates and the potential of human error negatively impacting manufacturing excellence. By implementing AI models like Cloud NC, Arcamed’s programming department has become one of the fastest and most reliable steps in the production process. With 80% of programming being completed through the software, project time has been reduced from upwards of two hours to a matter of minutes, giving engineers more time for optimization and quality assurance. Leveraging its extensive database of tooling and machine capabilities, Cloud NC optimizes machine-to-part assignment, minimizing human errors such as incorrect machine ID’s and suboptimal tool usage. 

Conclusion  

New technology has changed the standard for success in medical manufacturing. Arcamed’s strategic investments in automation and Cloud NC have increased efficiency, reliability, and cost reduction – all without sacrificing skilled workforce. Since 2023, costs have been reduced by 25% with order completion rates staying consistent. Automation has established consistent procedures, allowing consistent 8-week lead times at 98.8% on time delivery, 97.7% on time in full, and 97.7% orders defect free. This has enabled Arcamed to cultivate a reputation as an industry leader in speed, quality, and cost.