1. Catheter Tube Assembly Process
Team Members: Darren Brown
Art Chandler
Brian Tuchband

2. Assembled Catheter Tube
Project Introduction
3-Way Valve
Assembled Catheter Tube
Tube
Mission Statement:
Design a device to streamline the assembly process of the tube, TBV valve, and three-way valve.
TBV Valve

3. Current Process

4. Current Process

5. Current Assembly Problems
Operators at multiple stations required for assembly
Incomplete assembly leads to product waste and loss of money
Repetitive motion injuries experienced by operators
Carpal Tunnel Syndrome

6. Benefits of Automation
Cost Savings
Fewer operators are needed to assemble the product
Ergonomics
Repetitive motion injuries are significantly reduced through the use of automation
Productivity
Higher success rate leads to virtually no failed parts that need to be thrown away

7. Wants and Metrics
Wants:
Metrics:

8. Workstation Overview Cautionary Indicator Lights Hand Tie-Down Buttons
Emergency Stop Buttons
Tube Clamp
Pneumatic Valves
Optical Sensors
Positioning Actuators
Insertion Actuators
3-Way Jig
Main Circuit Breaker
TBV Jig
80/20 Frame

9. Process Description
Step 4: Apply primer to both ends of the tube using a brush
Step 11: Clamp opens to release the finished assembly
Step 3: Insert the 3-way valve into its jig
Step 1: Insert the tube into the clamp
Step 10: Insertion actuator inserts the 3-way valve into the tube
Step 12: Remove the finished assembly
Step 5: Place hands on hand tie-down buttons and press firmly to activate the machine
Step 9: Insertion actuator inserts the TBV valve into the tube
Step 2: Insert the TBV valve into its jig
Step 8: Clamp closes on the tube
Step 13: Machine resets to the original position
Step 7: Positioning actuator moves 3-way valve forward until sensor picks up the tube
Step 6: Positioning actuator moves TBV valve forward until sensor picks up the tube

10. Machine Demonstration
Success!

11. Prototype Development

12. Prototype Development

13. Full Automation vs. Semi-Automation
Level of Automation
Full Automation vs. Semi-Automation
High cost and intricacy of a fully automated system such as a robot would not be worth the minor advantages it offers over a semi-automated approach
With our semi-automated system, we can achieve ergonomic and productivity benefits at a much lower cost
Remaining non-automated tasks do not pose any risk to operator safety

14. System Validation

15. Setup Time Validation
Setup Time: The amount of time the operator interfaces with the machine before the automated process begins.
Using a stop watch, we measured the actual time needed to complete the following steps:
Procedure
Insert TBV valve and 3-way valve into
their respective jigs.
Insert the tube into the tube clamp.
Apply primer to both ends of the tube
using a brush.
Place both hands on hand tie-down
buttons and press down.

16. Setup Time Validation Exceeds Target Value Sample Size = 30
Average Setup Time = 11 seconds
Exceeds Target Value

17. Cycle Time Validation
Cycle Time: The time required to make one unit of product.
Using a stop watch, we determined the cycle time of the machine assembly process.

18. Cycle Time Validation Exceeds Target Value Sample Size = 30
Average Cycle Time = 23 seconds
Time (Seconds)
Exceeds Target Value

19. Success Rate Validation
Success Rate: The percentage of assembled products that pass the specifications of Terumo Medical (within 1mm of valve socket)
Using 40 samples, we determined how many products passed.
FAIL
PASS
Buckling Point
2mm Gap Between Tube End and Socket
Tube reached all the way to end of Socket

20. Success Rate Validation
# of successful assemblies
total # of assemblies
Success Rate = x 100%
Sample Size = 40
Mode of Failure: Tube Insertion Depth Not Sufficient
Fails to meet Target Value: 98%

21. Price Validation
Price: The amount of money it takes to build a production machine.
Final cost is calculated from the actual cost of the prototype in addition to the estimated costs of the hand-off components:
Glue Dispenser
Air Blow-Off

22. Project Budget
= Acquired from Terumo Medical
Meets Target Value

23. Safeguards Validation
Safeguards: The number of devices incorporated into the design of the machine to protect the operator.
Safeguards Included:
2 Locking Emergency Stop Buttons
2 Hand Tie-Down Buttons
Cautionary Indicator Lights
Exceeds Target Value

24. Path Forward Success Rate Deficiency Correction System Fabrication
Air Blow-Off
Glue Dispensing
In-House Qualification Testing
Installation Qualification
Operation Qualification
Process Qualification
Operator Training
Place System into Production

25. Success Rate Deficiency
Possible causes for failure:
Not enough insertion force
Clamp does not grip well enough
Insufficient primer application
Suggestions to improve success rate:
Use higher pressure air system
Optimize PLC code
Automate primer application process
Optimize flow control fittings
Redesign clamp (silicon coating, split-clamp design)

26. The Next Step Air Blow-Off Process
Air will be sent into the three-way valve at a high velocity to
remove excess primer
Implemented through the addition of small pneumatic hose
and spring-return valve
Controlled by the PLC
Estimated cost: $80
Glue Dispensing Process
Precision Dispensing System for Cyanoacrylate Adhesives
Developed and sold by EFD, Inc.
Precise material deposition improves bond strength by
applying the correct amount of material to parts
Rejects are reduced and product appearance is improved
Estimated cost: $5,400

27. Questions