A design defect that can create the biggestmanufacturing problem is arguably when ejection doesn’t work and/or potentiallydamages
the part. Ejection problems (failure of the part to eject cleanly andcompletely from the mold without warpage or other damage) can cause significantdelays in startup production and affect the cycle time for the process. Ejectionalso affects the cosmetics of the part due to the witness lines that arise fromthe use of ejector pins.A designerwho takes into account individual potential pitfalls can still err if therelationship between design factors is not considered since many designprincipals are interconnected. Gating, parting lines, and ejection are allrelated to each other, and a device manufacture may have used up their budgetby the time they realize it, which is often at the point when they expect to gointo full production.Designers often design the parts and take them to a
manufacturing facility latein the game expecting production to go off without a hitch. In reality,manufacturing design should be included throughout the design process so thatinteractions can be taken into account in the earliest part of the designphase. Choose a manufacturing vendor or experienced consultant early on andhave them do a detailed review of the interconnected factors that affectmanufacture. Serious delays and expense can result from molds not working, andthis can be avoided with careful planning and expertise.As manufacturers are well aware, healthcare professionals and their patientsalike demand that the medical devices they are using be made smaller,convenient, and discrete, while retaining complete efficiency andeffectiveness. For most areas of medicine, this is a challenge for thecompanies serving this
industry. It is an even greater obstacle to the successof a product when working with a technology that requires extensive experienceto deliver optimal results. The shifttoward smaller and more ambulatory equipment has challenged our traditionaldesign and manufacturing processes, explains Desloge. Advancements in theseareas, along with new advanced ceramic materials, polymers, and conductivefilms allow us to design high-performance heaters in small packages. This wasimpossible just five years ago. Due to the speed of the industry, it isimportant to be able to turn around product designs and prototypes in a timelymanner. We spend a lot of resources on “leaning out our design andmanufacturing processes Addressing a range of thermal solution needs in a variety of industries, including medical devices,Watlow is one of the largest custom designers and manufacturers of these typesof components. Under the direction of Desloge, the company will continue todevelop new innovations and offer its expertise as a leader in heatingtechnologies. In this interview with him, Desloge shares his thoughts onchallenges serving this highly regulated industry, reflects on his company’scapabilities and offerings, and comments on the industry as a whole. There are many trends and shiftsthat have impacted the industry over the last 10 years. For starters, therehave been economic changes—mergers, consolidations, and continued pressure toreduce costs—that look very different than they did in 1996. Regulatory changes . Technology drivers like scientific discoveries,new technologies, and new OEM equipment designs are focusing on real-time dataand equipment portability and the speed of tests have also changed thelandscape. In addition, general business changes like the focus on leanmanufacturing and product speed-to-market have created positive changes in ouroverall manufacturing process, which allows us to best serve the demands of theindustry. RoHS and WEEE are a fact of life,and Watlow has embraced the regulations. A couple of years ago, Watlowcommitted to meeting these excellent global environmental standards and we arecompliant. Most, if not all, of our medical customers simply expect us to meetthe standards, and we do. Medical device manufacturers willcontinue to meet future standards, because it is a requirement in a globalenvironment. Globalization of our customer basehas driven Watlow to establish technical support and manufacturing centers inMexico, Europe, and China. With localized support, we are able to satisfy thedemands of our customers in a timely manner. Building that infrastructure,while not difficult, is challenging technically and logistically. One of theother continuing challenges is the miniaturization of medical products, whichmandates constant innovation on our part. We welcome that challenge. As a division ofWatlow, Single Iteration brings together the collective knowledge of engineerswith experience designing and applying heating technologies for multipleindustries. Single Iteration generates new ideas and then evaluates, designs,and prototypes them to get products to market quickly. Single Iteration solvesdifficult thermal problems in shorter time frames than that achieved usingconventional iterative approaches helping clients get better thermal productsto market faster. Customers engage this level ofthermal systems engineering for a variety of reasons. They may be in search ofnew creative ways to improve a heating approach or they may be seekingengineering counsel from subject matter experts to ensure that success of theirchosen direction. Either way, close engagement of the development effort isalways done with an assurance not to disclose the nature of the developments. SingleIteration has worked to improve the heat efficiencies involved with intravenousfluid holding and transfer into the body to increase patient comfort. Additionally,we have worked directly on solutions to enhance cauterization techniques,provide fail-safe neonatal warming, and incorporate improved methods forapplying heat to tissue for surgical devices used to perform variousprocedures. Medical devices related to patientcomfort and healing are favorites because they improve the quality of life forthe patient. It always feels good knowing that you are doing something that hasa positive and noticeable affect on patients. Medical devices related to patientcomfort and healing have tremendous growth potential because they improve thequality of life for the patient.