Transform Medical Device Manufacturing with AI-Driven Precision
The medical device industry demands reliable precision and consistency. Product quality and compliance are so critical that it directly impacts the safety and well-being of individuals. Retrocausal’s AI solutions empower manufacturers to achieve exceptional quality, ensure compliance, and optimize costs in critical medical device production.
The medical device industry demands excellence at every step, but manufacturers face unique challenges that can impact productivity and compliance.
Defects and scrap in medical devices impact both patient care and production costs. In complex assemblies, ensuring consistent precision is essential for patient safety and regulatory compliance.
With tight protocols and complex validation requirements, maintaining consistent performance while meeting production targets requires new approaches to manufacturing excellence.
Manual inspection processes are time-consuming and prone to inconsistency. In an environment where every detail matters, relying on traditional methods limits both quality and output.
Rigorous regulatory requirements demand comprehensive validation and documentation of every assembly step, creating additional complexity in production processes.
Retrocausal’s intelligent solutions address these critical challenges, enabling manufacturers to maintain compliance while improving efficiency.
Streamline your assembly processes with AI-powered precision:
✦ Prevent errors with real-time alerts and live operator guidance
✦ Achieve full video traceability to support audits and compliance.
✦ Reduce defects and rework through root cause analysis and automated checks.
✦ Integrate seamlessly with existing MES systems
Streamline your assembly processes with AI-powered precision:
✦ Prevent errors during high-precision assemblies with real-time guidance and error-checking.
✦ Achieve full video traceability to support audits and compliance.
✦ Reduce defects and rework through root cause analysis and automated checks.
✦ Integrate seamlessly with existing MES systems
Accelerate continuous improvement with actionable insights:
✦ Reduce analysis time with instant time and motion studies.
✦ Enhance worker safety and productivity with ergonomic evaluations.
✦ Identify opportunities to optimize cycle times and cut costs.
Accelerate continuous improvement with actionable insights:
✦ Reduce analysis time with instant time and motion studies.
✦ Enhance worker safety and productivity with ergonomic evaluations.
✦ Identify opportunities to optimize cycle times and cut costs.
Streamline your assembly processes with AI-powered precision:
✦ Prevent errors during high-precision assemblies with real-time guidance and error-checking.
✦ Achieve full video traceability to support audits and compliance.
✦ Reduce defects and rework through root cause analysis and automated checks.
✦ Integrate seamlessly with existing MES systems.
Streamline your assembly processes with AI-powered precision:
✦ Prevent errors during high-precision assemblies with real-time guidance and error-checking.
✦ Achieve full video traceability to support audits and compliance.
✦ Reduce defects and rework through root cause analysis and automated checks.
✦ Integrate seamlessly with existing MES systems
Accelerate continuous improvement with actionable insights:
✦ Conduct rapid time and motion studies.
✦ Expedite and simplify line balancing and MODAPTS analysis.
✦ Design safer shop floors with ergonomic insights.
✦ Proactively identify and address potential failures.
Accelerate continuous improvement with actionable insights:
✦ Conduct rapid time and motion studies.
✦ Expedite and simplify line balancing and MODAPTS analysis.
✦ Design safer shop floors with ergonomic insights.
✦ Proactively identify and address potential failures.
Retrocausal’s solutions have delivered tangible results for medical device manufacturers worldwide.
➥ Enhanced production quality through real-time monitoring, reducing scrap rate by 60%.
➥ High Detection Accuracy:
82.4% success rate in error detection with only 2 false positives per 100 cycles.
➥ Improved cost efficiency by saving millions in annual production costs.
What makes Retrocausal impactful in medical device manufacturing?
Let Retrocausal’s AI solutions elevate your operational excellence – schedule a demo today!
Medical device assembly tends to be more error prone [1] than other discrete manufacturing sectors such as consumer electronics and home appliances, due to smaller lot sizes. First time yields remain between 60 to 85%, and manual-assembly related quality issues (human errors) are a major contributor to these poor yields. Emergency manufacturing requirements, such as recent needs to scale ventilator manufacturing for COVID-19 patients, cause yield and quality to be significantly worse.
Overall, the opportunity to improve quality costs for the medical devices industry is $4.75-$6B a year. In fact, costs of a single non-routine quality event, like a major recall, have been as high as $600M in medical device companies.
These stricter quality requirement imply an increased need to mistake-proof manual assembly processes in medical devices manufacturing. Our RetroActivity platform assists these manufacturers in three ways:
Due to regulations and ISO certification requirements, operators are often required to precisely follow a standard sequence of steps, and avoid batch assembly. Assembly Copilot, both with and without its projector integration has been deployed to encourage such compliance, and led to near 100% compliant results.
Assembly Copilot has been deployed on assembly of very small medical devices that can be sent inside the human body or transplanted into it. In these settings, Assembly Copilot is used with highly magnifying cameras including with microscopes, while the operator performs assembly also aided by magnifying glasses. We have also provided integrations with highly specialized instruments to achieve validation of certain steps. In a certain deployment where scrap rate was 30% and per unit cost in 1000s of dollars, customers were able to bring down scrap rate to under 5%.
Assembly Copilot has also been used when liquids and chemicals are involved in the assembly process. We are able to provide guidance on how to make computer vision validation work when transparent glassware is utilized in the assembly process; and help deploy digital Poka Yoke systems for these use cases as well.
It is critical to include all required components when kitting medical products e.g. Tourniquets, Shunt Kits, Stents, Perfusion Cannulas, and Catheters. In many cases, these kits are opened in emergency situations, and the medical practitioner cannot afford to have parts missing from the kits. Returns in these situations are not only bad for the bottom line in the short term, but the reputational costs of missing parts in Kits can be catastrophic. Assembly Copilot has been deployed in several medical Kit Packing use cases with success.
Brandin and his team help our customers with setting up the Pathfinder platform and getting up-to-speed on all the features and functionalities, in addition to assisting them with standardizing their processes where needed.
Brandin is a seasoned manufacturing leader, who has spent more than a decade designing and setting up assembly lines in both the US and China, optimizing them, and working with human operators to maximize productivity and quality.
Jesse works closely with our marquis customers to understand their needs, and figures out the best solution that immediately adds dollars to their bottom line.
Jesse has two decades of enterprise sales experience. He has held sales leadership roles at pioneering technology startups.
Andrey takes inventions and converts them into innovations. He leads our product engineering team to turn our scientific prototypes into robust customer-facing products.
Andrey co-founded and successfully exited a startup to immigrate to the US. He spent his next eight years building the core data science infrastructure for Amazon’s supply chain planning team, and the CV/ML infrastructure for Microsoft’s HoloLens organization.
Zeeshan focuses on delighting our customers by understanding their needs and defining product and strategy to meet and exceed these needs. He works closely with our sales leadership to grow our customer base.
Zeeshan was a scientific leader at Microsoft’s HoloLens division, where he invented AI technologies to assist frontline workers across industries. Earlier, he shipped IoT platforms and visual defect detection software for manufacturers at Siemens and MVTec GmbH.
Huy takes our product roadmap and figures out what’s achievable with today’s AI advances, and what we need to invent to solve our customers’ pain points.
Huy led teams of scientists and engineers at NEC and invented technologies for driver assistance systems that are part of 500,000+ Honda cars. He is an inventor on more than 20 US patents, and his research papers are cited by every lab from MIT, Stanford, and CMU to Apple, Google, and Baidu.
