Confidential: Multiplex System Pack Cooler

We organized a kaizen continuous improvement exercise that identified an opportunity for cost savings and risk reduction of the pack cooler sub-system. With support from the client, the robustly tested design changes resulted in significant savings per unit.

Client: Confidential

Product: Multiplex Testing SystemSystem

Cost Reduction Though Improvements To Manufacturability

Following a Value Analysis and Value Engineering (VAVE) exercise, we identified a cost-savings opportunity by changing the pack cooler in a multiplex testing system. The change improved manufacturability by reducing the labor time and requirement for specialized skills. Additionally, the design change improved lead time for manufacturing and reduced product risks through replacement of aging specialty tooling.

55%

Savings per Unit

Supported by Comprehensive Testing

Extensive fit, form, and function testing was performed on multiple validation prototypes. Design Failure Mode and Effects Analysis (DFMEA) and Process Failure Mode and Effects Analysis (PFMEA) tools were used to assess and address risks to performance, reliability, and manufacturability.

DESIGN CHANGES

Spun Aluminum Bowl

Updated design replaced the stainless steel double-walled, welded bowl with a simpler spun aluminim bowl. The reduction in required welds also reduced the risk of warranty issues caused by leaks.

Copper Tube Cooling Pipe

Welded cooling pipes replaced with copper tube that is formed and attached to the bowl along with a polyurethane overmold. This new overmold design also eliminated cracking issues caused by hoop stress in the prior design.

More Case Studies

Below are a selection of case studies highlighting the range of problems we’ve solved to deliver innovation and business value for our clients.

Life Sciences & Biotech

Not all innovative or complex technology is used in the clinic, but these systems benefit from many of the same principles used.

Mid to High Throughput Instruments

Whether we support the entire product or take lead on a subsystem, full instrument architecture is critical to success.

Benchtop & Distributed

Translating technical workflows of an assay into an automated process performed within a device.

Custom Process Automation

Transition from clinical to commercial scale manufacturing with our production-ready manufacturing and automation solutions.