Revolutionizing Large-Scale Production of Surgical Instruments with Cutting-Edge Technology"

Crafted with meticulous precision, surgical instruments are expertly manufactured in limited quantities. Specialized manufacturers prioritize designing structures and equipment with a paramount focus on achieving a remarkable level of flexibility in retooling.

 Precision surgical instruments are meticulously crafted products, typically produced in small quantities with utmost care. Manufacturers specializing in these precision tools prioritize a high degree of flexibility in retooling within their structures and equipment. This adaptability is crucial given the intricate nature of surgical instruments and the need for frequent adjustments in the manufacturing process.

In pursuit of enhanced production capabilities for one-time products in large quantities, a distinct process chain has been established. A pivotal component of this endeavor is the utilization of a two-spindle machine from Schwäbische Werkzeugmaschinen (SW), renowned for its exceptional repeat accuracy. Frank Pasuchert, regional sales manager at SW, emphasizes the demanding nature of precision mechanical surgical instrument manufacturing, citing high requirements and intense competition within the industry.

Among SW's clients is a company that has evolved from its humble beginnings in the 1980s into a medium-sized enterprise with approximately 130 employees. This firm currently produces around 1000 distinct utensils for surgical applications, with components crafted from premium biocompatible materials like stainless steel through intricate machining processes.

Despite the integration of modern NC-controlled machine tools, a substantial portion of the manufacturing process for these instruments involves manual operations. These surgical tools, comprising up to 40 different components, necessitate meticulous refinement, surface treatment, and manual assembly. Additionally, the presence of numerous variants and the requirement for small batch sizes underscore the importance of highly flexible retooling in the manufacturing systems.

To address challenges related to market competition and profitability, the company embarked on an ambitious large-scale production project two years ago. This venture involves the manufacturing of a specialized forceps for neurosurgery, a one-time tool with an annual demand reaching hundreds of thousands of units. The forceps, made of aluminum, serves the dual purpose of grasping tissue components and halting minor bleeding with electrical pulses. The manufacturing process, although seemingly straightforward, is intricate and time-consuming, involving various mechanical and manual work cycles, many conducted under a microscope.

The cornerstone of this innovative process is the SW BA 321 machining center, an automated dual-spindle system with remarkable efficiency. Designed for milling forceps halves made of aluminum, the machine boasts a custom automation unit for material supply and the removal of milled parts. This specialized system achieves unparalleled productivity, producing two fully milled forceps halves in just three minutes. The automation allows for continuous operation, largely unsupervised, and delivers superior repeat accuracy, surpassing the throughput performance of other machining centers on-site.

The decision to collaborate with SW was influenced by the productivity of the double spindle concept and the company's proven references. The proximity of SW's services also played a role in the partnership, ensuring swift responses and travel times for both development and potential service calls. The collaboration began in 2017, focusing on the automation of machining processes, leading to the development of a specialized machine based on the BA 321 model.

The forceps halves are carved from press-drawn sections, and the automation system handles the material supply, milling, and removal of parts. The joint development and project planning phase lasted until June 2018, followed by the installation and commissioning of the system in mid-2018. Since then, the machine has undergone testing and programming for various product variants, with full-scale production commencing in November 2018.

The success of the project is attributed to efficient joint development, prompt support, and comprehensive service. The use of SW's online service, "life data," ensures continuous monitoring of essential machine parameters. This real-time connection allows for immediate action in case of issues, including remote diagnostics and consultation through "life help." The company has expressed satisfaction with the quality of the machine, the support received, and the efficiency of SW's services. An additional BA 321 has been ordered to meet the growing production demands, with delivery expected in August 2019.