From human variability to robotic repeatability

In the medical field, some things will always require a human touch. For example, the connection between doctors and patients can’t be adequately replicated by robots, especially when patients are struggling with serious health conditions and need reassurance and empathy. However, artificial intelligence (AI) has already made a significant impact on healthcare and its influence will continue to grow. Robot-assisted surgeries improve precision and control and enable minimally invasive surgeries (MIS). AI algorithms can analyze imaging data to help doctors diagnose patients more quickly and accurately. Robots can also be used for automated inspection of medical devices, increasing accuracy by removing the potential for human error.

Without the use of AI, medical devices are inspected by hand using tools such as calipers and micrometers as well as visual inspection. An operator measures and collects data by hand as well, writing down measurements and results. Defect identification is dependent on the skill and visual acuity of that operator. Inspection is partly carried out by visually examining the part and looking for defects that could compromise product integrity. In an industry that must meet stringent regulatory requirements and ensure user safety, that’s a lot of pressure for a human worker.

Robots, however, don’t feel pressure or stress – or fatigue, unlike humans who may begin to miss signs of defects during the course of a strenuous workday. Through no fault of their own, humans make mistakes, because they’re, well, human. A robotic inspector can work tirelessly and provide consistent results. Robotic inspectors can fixture a part mechanically using repetitive clamping or workholding and use a variety of technologies and tools to measure the part accurately and repeatedly. Robots can also automatically track data related to the components. That data can be uploaded into a computer or SQL Server and even connected permanently to the component using a serial number.

Finding a place for automation

Automation eliminates the variability inherent to human inspection as well as human error.

“There’s a subjectivity to the entire basis,” says Brandon White, director of sales for the +Vantage business unit of robotics integrator Acieta. “You can’t put an objective dimensional variable behind a visual inspection. Using a micrometer or a caliper, for instance, and maybe the inspector didn’t square it up with the component correctly, maybe they didn’t load the tool into the fixture with the appropriate method, and it was sitting slightly off, and we got a false reading. There’s just a lot of variability.”

Acieta assists companies in implementing robotic solutions in various industries, including medtech. Acieta’s services include developing tailored solutions, setting up machines, training staff, and verifying the automation is fitting the form and function of the company’s intended use before handing it off to the client. The +Vantage business unit specializes in inspection process and assembly for customers in the medical space, as well as aerospace and automotive.

“We’ll do a complete walkthrough of their facility, we’ll bring in several subject matter experts, depending on the part that they’re manufacturing or assembling,” White continues. “Not every medical manufacturer is going to know offhand what they want to automate, but they may just know they need to automate. So, we can extend the help to actually go to their facilities, evaluate what’s most conducive to automation, make the recommendations, and then draw out and support them in developing the business case, supporting with the technology and the information behind it, and provide them the presentation to push this through and turn it into a reality for their facilities.”

Facing the fear of the unknown, finding value

Many manufacturers hesitate to implement automation for several reasons. Concerns include not having the right capabilities or training, as well as the fear that robots will take the jobs of humans. This anxiety is understandable but unfounded, according to Acieta – robots, the company asserts, help create jobs. Robots take menial, repetitive tasks from humans, freeing them for more varied and fulfilling work. In addition, automation increases productivity, which leads to advantages such as shorter lead times, lower part cost, and more consistency – all potentially bringing in more business and more jobs. Viewed through a wider lens, the increased productivity robots make possible helps lower costs, which allows for the growth of a larger domestic workforce.

Acieta tackles companies’ concerns by providing comprehensive training, education, and 24/7 maintenance with rapid-response service teams to minimize downtime. By ensuring operational security and demonstrating how automation enhances safety, productivity, competitiveness, and overall value, Acieta helps manufacturers embrace robotics with confidence. Manufacturers can calculate their return on investment (ROI) in a few ways, White says. First is looking at the ability to shift human operators into more value-added positions, allowing automation to take over inspection duties. Second is considering the costs of what can happen without automation. What’s the cost of return, and what happens in the case of product quarantine, recall, or worst of all, injury to a patient? Automation can provide peace of mind in addition to improved quality. Finally, using robots allows manufacturers to measure 100% of their product volumes and track 100% of their data.

“Between those three things, you can essentially map out where that return is and how long it would take to receive,” White says.

Ease of transition and peace of mind

FANUC is a valued partner of Acieta, offering a comprehensive range of robots and cobots for various applications. When consulting with each manufacturer, Acieta carefully assesses the specific needs of their application – such as reach, payload requirements, and cycle time – and recommends the most suitable solution from the FANUC portfolio. Acieta’s FANUC certification ensures its engineers are experts in these systems, and by stocking spare parts for emergency situations, Acieta can significantly reduce downtime. According to Acieta, most robots, contrary to common beliefs, are affordable, reliable, and relatively easy to program, even for non-experts. They can be used effectively in low- to medium-volume manufacturing, not just high-volume, which is key for medical device manufacturing where high levels of customization means parts are typically produced in high-mix, low-volume (HMLV) production runs.

In medical device manufacturing and inspection, robots can be extremely valuable, improving consistency, accuracy, and productivity while allowing workers to spend their time and energy on other tasks. Automation technology is growing quickly, and it’s not going anywhere – it’s already infiltrated most industries, requiring companies to rethink their operations. In most cases, automation brings improvement, but it does take some adjustment. Because of the intimidation factor, many manufacturers are wary of automation, but Acieta’s goal is to make the transition to robotics as smooth and easy as possible.

Acieta
www.acieta.com

FANUC
www.fanucamerica.com

About the author: Clare Scott is associate editor for Today’s Medical Developments magazine. She can be reached at CScott@gie.net or 216.393.0314.