Telesis laser provides seamless, quality marking and excellent short term R.O.I.
Smith & Nephew Orthopaedics, a premier global medical devices company needed a custom laser solution to mark over 3,000 different medical devices. This Memphis, Tennessee-based company markets clinically superior products, principally in orthopedics, endoscopy and wound management. They needed a number of specific nesting fixtures to laser mark a variety of devices - from intricate measuring tools to joint replacements for surgical use. The cost of developing and manufacturing these fixtures was done in house, but costs were astronomical. In addition, their laser marker suffered both repeatability problems and ongoing maintenance issues.
Their objective is to develop and market medical devices to deliver cost efficient solutions, significant physician advantage and real patient benefits. This continuous process of supplying new and innovative products is supported by a substantial R&D investment to deliver new levels of healing to patients throughout the world. As quality of mark degraded with their old system, the cost of keeping the highest standards of quality to their customers escalated. So, it was not surprising that it was time to search for a new marking solution that could help them meet their quality and profitability needs.
The Telesis Technologies Custom Engineering Group worked closely with Smith & Nephew's Senior Manufacturing Engineer, Scott Sherman, to "think outside the box" in designing a custom system for handling and providing the consistently high quality marks necessary for surgical applications. A Telesis ProScript 90Watt YAG Laser System, along with a robot and custom workstation, now provides the cost effective solution to handle and mark the 3,000 plus medical instruments and devices. The tabletop robot provides efficient handling and presentation of devices to the laser field for marking. Specific fixturing is eliminated which reduces operating costs, and exact marking repeatability significantly lessens wastage from discarded, mismarked product.
To provide synchronized communications, Telesis software developers wrote a program with a single interface between the robot and the laser marker. An added feature allows remote development and download of robot and laser programs to the Telesis system. Obviously, this versatile Telesis software provides synergistic solutions not previously available. Another feature of the Telesis ProScript software is that AutoCAD drawings and DXF files can be imported as Adobe Illustrator files. This simplifies programming and makes it easy to add logos when necessary. Each pattern is developed from the desktop and adjusted at the marking station. In addition, the operator has the ability to actually see digital pictures within the program showing the exact location of robot pickup. Any changes, then, are easily made "on the fly", saving valuable time and reducing errors while providing a very high level of quality.
The Telesis Custom Workstation provides a central platform for computer, monitor, laser, pendant and robot. The robot and laser controllers are conveniently and safely housed underneath the counter. Manufactured of extruded aluminum with metal top plate, the workstation takes up only six feet by four feet of floor space. The metal top plate allows ease of fixturing through adjustable stops or magnetic nesting. The Telesis ProScript remote operator pendant offers ergonomic, friendly control for pattern selection and safety lockouts.
According to Scott Sherman, "The robotic laser workstation that Telesis built for Smith & Nephew is performing superbly. It has increased the accuracy of our marks by an order of magnitude. Our validation study gave an average CPK value of more than 6, and we have some very complicated and precise marking requirements. We are seeing at least a 50% decrease in set-ups, and a 30% increase in productivity. Telesis did an excellent job of integrating the workstation. Before the first month of operation was over, there was serious discussion about when we will purchase our NEXT workstation."
The Telesis custom integrated Laser/Robot system gave Smith & Nephew both a seamless, quality process and a short term return on investment. Telesis' Applications Engineering Team provided a strategic solution to help put this premier global medical devices company on a fast track to exceed expectations.
To watch a video of the ProScript Laser Marking System in action, go to http://www.telesis.com/video/mvc-001v.mpg .
Source: Telesis
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