Executive Summary
i2i Engineering, a leading automation company specializing in custom manufacturing equipment and automated assembly systems, partnered with a global life sciences manufacturer to dramatically increase well plate production capacity.
Facing severe labor shortages and surging demand during the COVID-19 pandemic, the client needed a fast, reliable, and scalable automated assembly system to replace manual operations.
Within a demanding 12-week timeline, i2i Engineering, a trusted automated assembly system supplier, delivered a turnkey automation solution that:
- Reduced labor requirements by 50%
- Increased production throughput
- Improved worker safety and ergonomics
- Minimized product loss due to breakage and contamination
Assembly Layout: Existing Manual Process
4 Operators per Product Line
- Operators 1 & 2: Insert well plate components into egg crates
- Operator 3: Tamp well plates & inspect
- Operator 4: Supply empty egg crates & remove finished product
Project Highlights
This project highlights i2i Engineering’s ability to deliver high-tech automation for customized products, optimizing manufacturing performance for the Life Sciences Industry.
Overcoming Manual Limitations
The Challenge:
Rapid Deployment of a Custom Automated Assembly System
The client faced two urgent challenges:
- Labor Shortages: Their manual well plate assembly process required 12 operators for three molding lines and were unable to meet increased demand.
- Escalating Demand: COVID-19 drove a dramatic spike in the need for laboratory products, creating urgency for an automated, scalable solution.
Complicating the project was the need for rapid automation deployment, the full system had to be designed, built, and commissioned in just 12 weeks.
Automated Assembly Solution
The Solution:
Customized, High-Tech Automated Assembly System
i2i Engineering developed a custom automated assembly system featuring three integrated automation solutions:
1. Automated Transfer System
A custom conveyor automation system captures molded well plate components directly from molding machines, maintaining precise orientation. This eliminates manual collection, reducing product loss from breakage and contamination.
2. High-Speed Pick-and-Place Assembler
An advanced high-tech automation system quickly picks and places 48 well plate components into egg crates in a single cycle, significantly speeding up the well plate assembly process and minimizing operator intervention.
3. Automated Tamping, Inspection, and Stacking
A fully automated station tamps components into place, inspects seating using vision inspection systems, and stacks completed plates into units of 25, creating a workflow buffer and improving quality assurance.
Assembly Layout: Automated Solution
2 Operators per Product Line
- Operators 1: Load empty egg crates into Transfer & Assembly Station
- Operator 2: Supply empty egg crates & remove finished product
4. Overcoming Challenges: Agile Engineering and Proactive Procurement
Despite global supply chain disruptions, i2i Engineering successfully executed the project by:
- Proactively Prioritizing Procurement: Ordering critical components early to avoid lead time delays.
- Adopting Agile Manufacturing Methods: Rapidly adjusting designs and processes to meet evolving requirements without impacting the schedule.
Remarkable Results Achieved
Results: Improved Production, Efficiency & Safety
The new semi-automated well plate assembly system delivered outstanding improvements:
- Labor Efficiency: Reduced operator needs by 50% per molding line
- Increased Throughput: Matched the output of three molding machines, exceeding previous manual limits
- Higher Product Quality: Minimized handling damage and contamination, increasing manufacturing yield
- Enhanced Safety: Lowered repetitive strain injuries, improving ergonomic conditions for staff
Conclusion
Your Trusted Automated Assembly System Provider
i2i Engineering’s innovative well plate assembly automation solution enabled the client to meet growing production demands, control labor costs, and protect workforce health.
As a proven automation company and automated assembly system supplier, i2i Engineering delivers high-tech automation for customized products across the life sciences and broader manufacturing sectors.
Transform Your Production
Looking to scale your production with a custom automated assembly system? Contact i2i Engineering today to discover how we can help your business achieve operational excellence.