Automated End-of-Line Tester With RFID Tagging

How HAHN Automation Group helped one medical device manufacturer scale-up production while protecting IP

A large manufacturer of pathology solutions faced increased demands for their tissue-sampling probes; let’s call this customer, “Casey.” Casey forecasted volumes rising nearly 400% over the next five years—and they needed an additional end-of-line tester to meet those goals. Casey also wanted to add RFID tagging to protect their intellectual property as their products began to be sold internationally.

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  • Improved cycle time with added features
  • Intellectual property preserved
  • Accuracy checked during production

 

Challenge 

Casey needed a system that would meet the large and upcoming volume demands and improve testing consistency with an end-of-line tester. Additionally, Casey wanted to incorporate RFID tagging to protect intellectual property in their devices sold internationally.

 

Developing a Solution 

Having designed and built a previous test system for Casey, we looked for ways to enhance the original design to address the needs for improved cycle time and added security features.

We began by researching techniques for reading and writing to the RFID tags in a secure manner. Our controls engineers conducted feasibility checks and found that the sensor placement was critical in order to read/write without touching the handle of the device. This information was used to influence the design of the overall system.

Process Overview

  1. An operator loads the device onto the system with the probe cutter open and seal applied; thrubeam fiber optic sensors verify that the product is seated properly in the nest.
  2. The probe assembly is vacuum leak tested (pressure decay) while a laser micrometer verifies that a precise product feature does not exceed the specified acceptable range. Once these measures are in place, the system uses a pneumatic clamp to secure the device while an integrated drive system performs a torque test on the device actuation wheel.
  3. If all three tests are passed, the device is laser marked with a serial number. The same serial number is written to the RFID tag along with the test results. If the product failed, the RFID tag is locked.

 

Cycle time: Improved by 33%

Results

The equipment allows the tests to run simultaneously before writing to the RFID chip, helping decrease the overall cycle time despite the added features. The resulting system improved cycle time by 33% from the original tester—and has allowed Casey to more than double their production.