We begin our process by listening to your needs for increased production, new product machinery, machinery replacement or upgrades, reduced labor costs, or reduction of ergonomic strain. You tell us what your requirements are for product output, space requirements, system constraints, CGMP requirements, and ergonomic requirements.
Once we have heard and understand your needs, we begin the Quoting Process. In this process we obtain details of the project, examine sample products, and review constraints and environmental conditions. We also begin machine design brainstorming for the best possible solution and explain our concept by showing a detailed explanation of what we can do for you.
Upon the receipt of your purchase order we begin our Design Process. This process is based on sound concepts and knowledge of part handling. We design high run-time machines that have with minimal wear components, allow for flexibility with change-over in mind, reduce or eliminate ergonomic issues, meet CGMP standards and strive for the highest Overall Equipment Efficiency (OEE).
The next stage is the Design Review Process which allows us to go over the design with you at our facility or via web conference and provide open communication with our designers of your system. At this time, we would also review the electrical layout and software requirements and schedule any design changes before manufacturing, to make sure the design and layout meet your requirements.
The Machining Process begins upon the sign-off of the machine design. During this stage we begin with a CAD (Computer Aided Design) to CAM (Computer Aided Manufacturing) operation, creating electronic files for our CNC machining centers. All the machined parts are then created in one of our four CNC machining centers, which include 4-axis machining capability.
Following that process is the Assembly Process where the mechanical and electrical systems are completed by skilled technicians and overseen by our Systems Quality Engineer in order to complete the validation process.
The Software Development Process usually starts following the design review. The entire software package is developed in RS Logix 5000 software using a standard template. This provides a uniform layout for all machines. It also allows for custom features to be easily added and provides open source codes for viewing or modifying, which is required for validation and CFR 21 Part 11 compliance. In addition, we utilize RSView Studio-Machine Edition software for HMIs with the use of graphic alarms throughout the software.
The Validation Process of the machinery and lines are completed by our Systems Quality Engineer, who oversees the entire assembly process. We start with initial sub-assembly inspections ensuring the functionality and that it meets the designer’s intent. Next, a dry-run of the complete system overnight for a minimum of one week is conducted. System checklists are made each morning, noting and addressing any issues. We develop a plan to break the system into sections and debug each section to ensure overall system functionality. Finally we qualify the system for Factory Acceptance Testing (FAT) and make sure to exceed the customer’s expectations.
Once our machines ship to your facility we provide a Start-up and Training Process. This trip is scheduled by our Project Manager and is completed by the lead technicians that assembled and debugged your system, along with the Systems Quality Engineer. During this process we fully train your employees on how to operate, maintain and service the machinery. This training can also be found in the documentation package we provide with each system. The package includes the bill of materials, mechanical assembly drawings, electrical schematics, required preventative maintenance schedules, a list of replacement components (recommended spare parts), the PLC/HMI program, descriptions of HMI screens, homing procedures for training and debug, and finally all the purchase components’ literature and documentation.
Our Service & Support Process includes rapid response with first class service, which is addressed through our Project Manager. Our support is available via phone, email, or in-person when you need it.
Our Advanced Integration Service allows us to provide you with a full packaging line of our machinery and other OEMs machinery in order to provide a high OEE for your entire line. We provide other OEMs with specifications of what we need to integrate their machinery with ours to ensure the communication, start-up, and maintenance operations of the line are easy. Detailed reviews are completed to ensure the electrical and mechanical features all fit to what your specifications require. We also use graphic alarms and overall line monitoring to ensure the highest OEE of the line is maintained.
Our process allows you to “Get what you want, not what you can have”. If you want a feature added, we process a change request to accommodate your needs. We work with you and accept feedback on all details and features to ensure your system meets your needs and has a high Overall Equipment Efficiency (OEE).