Increasing Output and Quality with Validated Inline Processes
As a globally active company specializing in plastic injection molding automation, HAHN Automation Group partners with leading manufacturers to optimize complex, highvolume production processes. Our customer, an international healthcare company, needed support in the redesign and optimization of an existing manufacturing process for cuvettes — aiming for higher output, improved quality, and faster time to production.
#MedTech #Diagnostics #Cuvette #VarioTIP
- VarioTIP® concept for complete cavity sorting and end-to-end traceability
- High flexibility through modular design
- Smallest footprint
Challenge
The client planned a major product redesign to achieve significant material savings, which introduced several challenges. The manufacturing process needed to be optimized. An additional process (leak-test) had to be integrated into the inline downstream approach, replacing the previous decoupled setup. The project also required managing a substantially higher output while maintaining strict medical-quality standards. The key challenge was to transfer all operations into a single inline process and develop solutions capable of meeting these new demands.
Developing a Solution
HAHN Automation Group applied a structured, collaborative approach with a cross-functional team of experts covering automation, tooling, welding, and quality assurance working closely with the customer from the outset. Each key sub-process — high-speed part removal and leak testing — was analyzed based on the new requirements, and initial concepts were evaluated using simulations. Dedicated feasibility studies and mock-up tests validated each process, creating a solid foundation for the final machine concept.
Close collaboration and systematic risk mitigation enabled the confident implementation of a high-cavity system in the first production step.
