Bone Screws & Implants Marking Application

Manufacturers of bone screws, bone plates, artificial joints and other implantable devices face many challenges. Producing safe and flawless devices is by far the most important consideration because an implant is inserted into the human body where it often remains permanently. In terms of regulation, manufacturers must comply with complex government product labeling requirements for reasons of safety, traceability and compliance, among others. In order to produce these medical devices with the highest quality and impeccable precision, there is a constant demand for exceptional laser marking systems and dedicated service partners. In this Industry Solution Guide, let Telesis demonstrate how we are the best choice in meeting these challenges.

The Telesis Solution – F Series Fiber Laser

Patient well-being and product safety are the top priorities of device manufacturers because implants like bone screws and artificial joints remain in the body foran extended period of time – often permanently. Special care must be made to ensure that the implantable device is resistant to bacterial growth and maintains its corrosion resistant quality. When the material surface is damaged during the marking process, bacteria may accumulate, which can potentially cause infections and other serious problems. The Telesis F Series line of high performance fiber lasers is capable of making delicate annealed marks without any superficial damage, safeguarding the integrity of the product. This series of low-maintenance yet highly dependable lasers produce consistent and precise results.

This is a laser marking application from Telesis Technologies
July 24, 2017 by Johny Chen, Telesis Technologies, Inc. |
Bone Screw Industry Solution Guide

Tri-Phase Automation is a Telesis distributor in Wisconsin and IL
Contact Tri-Phase Sales or Get A Quote

Surgical Instruments Marking Application

Marking Surgical Instruments with Telesis Marking Technologies, Inc.

The Customer Challenge
According to the U.S. Department of Commerce, there are more than 6,500 medical device companies in the U.S. with a total market size of $148 billion. The most active sub-category in the industry is surgical and examination instruments (based on value of export shipments), which includes products ranging from scalpels to intricate catheters. With strict regulations and proposed new rules (Unique Device Identification system) by the U.S. Food and Drug Administration and the European Union, Telesis can provide a wide variety of reliable and innovative solutions to often difficult and challenging marking tasks.

The Telesis Solution – Fiber Laser Marking
The F-Series fiber lasers are a versatile product robust enough for heavy industrial etching and delicate enough for annealed marks. Typical for medical applications are annealed marks that cause no damage to the surface or the material and maintain the corrosion resistant nature of the medical instruments. This form of non-invasive processing is crucial in the prevention of bacterial accumulation. Whether it’s banded titanium needles or high-grade stainless steel scalpels, this laser can mark them with precision, consistency and reliability.

This fiber laser marking application is from Telesis Technologies.
Surgical Instrument Industry Solution Guide
July 24, 2017 by Johny Chen, Telesis Technologies, Inc.

Tri-Phase Automation is a Telesis distributor in Wisconsin and IL
Contact Tri-Phase Sales or Get A Quote

So many labels, so little time. Just use Checker

An application success story from Cognex

OTE Group produce special hydrating, cleaning and lubricating fluids for the lens care market. As well as their own three product lines they deliver more than 100 private labels to customers with their own brands. Delivering the finished products all over the world, they need to be sure that all bottles reach their destinations in perfect condition and in good time.

When faced with the challenge of boosting their quality the company decided to use the Cognex Checker® vision sensor to ensure that the production code is present and also to check if the label is on the bottle. Using Checker ensures that quality control is improved meaning better traceability and faster more reliable production. OTE Group maintain high quality standards conforming to ISO standards for filling and manufacturing and so they cannot afford to take chances.

Checker has given OTE peace of mind with a 100% reliable inspection of each bottle – both their codes and labels. Before this they relied on random sampling but this is not enough to satisfy the strict requirements of their customers from the medical and pharmaceutical industry.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Track and trace of pharmaceutical folding boxes with Cognex vision systems: certain to be original

Cognex taking a role in the fight against counterfeit pharmaceutical packages

An application success story from Cognex

According to the EU Commission, the rate of counterfeit drugs has risen by around 400 per cent since 2005. The Customs departments of European countries seize up to 2.4 million counterfeit pharmaceutical packages each year. According to World Health Organization (WHO) estimates, it is assumed that around 10 per cent of all medicines worldwide are counterfeits.

The DataMan 200, developed specifically for the efficient reading of even the most complex Data Matrix and linear barcodes, verifies that the label is applied in the first step. As the world’s first scanner with autofocus, its liquid lens ensures fast and highly accurate focus settings without any mechanical parts. To ensure optimal lighting conditions, it has integrated illumination with laser alignment.

“A significant contribution to the success,” according to Krempien Petersen CEO Stefan Klöpping, “has been because of internationally standardized and proven components, such as the DataMan 200 and the In-Sight 5613 vision system from Cognex. Only 40 pieces out of 250,000 during the two-shift operation are scrapped each day, a successful number for any operation.”

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Optical inspection of pharmaceutical labels

A customer success story from Cognex.

A medical device manufacturer needed to inspect for the presence of two dowel pins and a plastic cover on a product. Traditionally, this inspection was done manually, but was prone to operator error and resulted in rework costs. Traditional photoelectric sensors could not adequately identify the missing components due to their small size and position.

A Checker® vision sensor was installed. The manufacturer wanted Checker installed in an inspection station. An operator would place the component into the station and would manually trigger Checker to perform the inspection. Checker uses two contrast sensors to inspect for the missing dowel pins and a pattern sensor to inspect for the missing plastic cover.

Manual inspection errors were eliminated and product quality was increased. Rework costs declined dramatically and production line speed was increased.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Medical Device Assembly Check

A Medical Products Application From Cognex.

The Challenge

A medical device manufacturer needed to inspect for the presence of two dowel pins and a plastic cover on a product.

Traditionally, this inspection was done manually, but was prone to operator error and resulted in rework costs. Traditional photoelectric sensors could not adequately identify the missing components due to their small size and position.

Application Solution

A Checker® vision sensor was installed. The manufacturer wanted Checker installed in an inspection station. An operator would place the component into the station and would manually trigger Checker to perform the inspection. Checker uses two contrast sensors to inspect for the missing dowel pins and a pattern sensor to inspect for the missing plastic cover.

Manual inspection errors were eliminated and product quality was increased. Rework costs declined dramatically and production line speed was increased.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Device Product Number Match

Medical Products Application by Cognex.

Device Product Number Match

The Problem

A Medical Device manufacturer required a Product Number inspection during their production process. Traditionally, this was done manually, but was prone to operator error and resulted in rework costs. Traditional sensors could not easily read the product numbers, and expensive Vision Systems were not practical.

The Solution

A Checker® vision sensor was installed. The manufacturer required a solution where a part would be manually inserted into a precision fixture and when an operator hits a start switch (external trigger) Checker would perform the Product Number inspection. Checker met this goal using two pattern sensors to inspect for the matching Product Numbers based on an internally stored template. As a bonus feature, Checker’s ability to store settings for up to 16 jobs allowed the manufacturer an added benefit to quickly enable line changeovers.

The Benefit

Quality was improved with the manual inspection replaced with Checker. Rework costs declined dramatically and the manufacturer was able to leverage Checker’s job changeover capabilities to decrease errors during line changeovers.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer evaluations and technical support to help our customers solve their applications.

Creating a fully automated pharmacy warehouse

An application customer success story from Cognex.

Increased efficiency and process optimization have become hot topics for the professional pharmacist. An important technology that assists in overall customer service is a fully automated warehousing system. With these types of systems in place, more time is available for customer contact—valuable time that can be used to generate additional sales. In addition to the quick picking of products, the initial delivery and warehousing of products is also important because several hundred new products can arrive each hour at large pharmacies.

The fully automated warehousing system at KLS Steuerungstechnik GmbH, located in Germany, achieves this with ease thanks to image-based DataMan 500 barcode readers from Cognex. The DataMan 500 scans each product as it arrives and transfers the data to the company’s enterprise resource planning (ERP) system so all warehoused items are cataloged. As a stand-alone system, the DataMan 500 can deal with an hourly throughput of 450 units.

The DataMan 500 image-based code reader replaced laser scanners that KLS had previously used. DataMan 500 offers variable focus liquid lens technology, which allows it to achieve a highly flexible depth of field—even when the package moves extremely fast. With the aid of its IDMax® code reading software, the DataMan 500 achieves higher read rates than a laser scanner and identifies codes that a laser cannot, for example, distorted, blurry, small, or extremely low-contrast codes. Even codes on reflective packaging pose no problems for the DataMan 500. It also keeps pace with the high speed system by achieving image capture rates of up to 1,000 frames per second. “With the DataMan 500, we especially appreciate its speed and accuracy,” says development engineer Daniel Hauch of KLS Steuerungstechnik. “It offers us considerably more handling flexibility than our previous systems.” The new system reduces the workload of pharmacies substantially and opens up new revenue potential.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

Detection, alignment and inspection of product labels

Cognex Checker® always checks the label carefully for AstraZeneca.

An application solution story from Cognex

Problem

AstraZenec,one of the leading pharmaceutical companies in the world, needed to improve the accuracy of label detection in order to maintain production quality. The problem arose from the assistant system counting product labels as traditional electric-photo sensors often encounter errors when checking the edge of two neighboring labels. These sensors are not competent enough to meet such high speed production requirements. In order to reach zero defect level in production, AstraZeneca needed a more accurate vision system to count label numbers, to check whether the edge of the neighboring labels on the production line are correctly aligned and to raise the alarm when an error occurred.

Solution

AstraZeneca performed a series of tests on their production line using vision systems from Cognex as well as from several other vision suppliers. While they found that all the systems tested met basic production requirements, the Cognex Checker stood out as the intelligent sensor capable of going further.

Benefit

Thanks to the stability and accuracy of Checker, the quality of detection and counting is maintained and a high level of productivity is guaranteed. Costs are reduced while resolving a difficult problem. AstraZeneca is considering expanding the application to inspect date codes and inspect packaging.

Tri-Phase Automation is a Cognex distributor in Wisconsin. We offer machine vision evaluations and technical support to help our customers solve their applications.

RFID Monitors Hose Connections

A solution from Pepperl+Fuchs

RFID readers and tags monitor hose connections
RFID readers and tags monitor hose connections

Application
In chemical, pharmaceutical, and aseptic process equipment, process components and liquids must be transported from their storage tanks to a process reactor. It is of vital importance that these components are not spilled and that the wrong liquids are never introduced into the reactor, as this could result in costly process interruptions that must be prevented.

Requirements
Small RFID read heads are mounted near the metal hose couplings. Reliable operation under harsh environmental conditions is assured.

Customer advantage
Process security and prevention of downtime by eliminating the introduction of the wrong process components and liquids.

What has been done
Chemical plants typically utilize continuous process methods. Process interruptions and errors frequently result in significant yield losses and associated costs. In order to protect such processes with nearly 100% reliability, and to exclude any human and external machine introduced errors, the hose couplings are equipped with RFID technology. A hose connection with an incorrect process medium for the current process can be securely identified. The transport valves for this invalid connection will not open and the error will be clearly displayed, allowing an immediate response by the operators. Important for these kinds of applications are reliable RFID hardware components and RFID tags that can be flush mounted inside a protective metal collar. In food and beverage applications, hose and pipes are regularly flushed using sanitary cleaning solutions. In this case, it is also important to securely separate the cleaning agents from the food.

Monitoring hose connections with RFID guarantees the introduction of the right material at the right time and assures that the correct measuring equipment is used for the process.

Tri-Phase Automation is a distributor of Pepperl+Fuchs in Wisconsin.  For more information Contact Tri-Phase Automation.