Challenge
Design and build an automatic, High Mix, Made-to-Order (MTO) production line for contact lens blister sortation, fulfillment, labeling and cartoning with fail-safe validation.
System Input
Unlimited number of random SKU’s in single or 3 packs as well as Made to Stock (MTS) triple blisters from other production lines.
Solution
A custom designed system leveraging standard inspection, labeling and packaging modules to conserve cost and accelerate time to market. The innovation that led to success is the random retrieval Sortation Matrix.
Operational Steps
- Random blisters are automatically fed from previous autoclave process
- Sort/collate the blisters to the Sortation Matrix or directly to packaging
- The SM has 1300 storage locations each holding 6 blisters for a total of 7,800
- Blisters are removed automatically from the Sortation Matrix based on MTO directions from the Factory Information System (FIS)
- On-demand auto-retrieval of blisters from the SM to fill orders
- Blister is placed to a distinct location on the labelling conveyor
- Blister is labelled / vision inspected; good part or reject decision is made
- Based on the next in line order, the ‘High Mix’ cartoning system will:
- Erect the correct size carton for this customer order
- Laser etch carton
- Vision inspect the mark
- Load blisters to the carton based on the order (MTO)
- Output packaged sizes – 3 pack, 6 pack, Diagnostic/Trial singles
- Vision verify packaging
- Insert leaflet, close and seal
The MTO manufacturing line runs at 2000 blisters / hr and was designed in accordance with FDA requirements and EC Medical Device Directives. The output of this system is fulfilled and validated orders and another happy PMD client.