Enhancing Product Development at a Leading US-Based Medical Devices Company

Introduction

This case study explores the transformative impact of integrating DFMPro with the Creo CAD platform at a leading US-based medical device company specializing in eye care devices. As the largest eye care device manufacturer globally, the company is committed to innovation and cutting-edge technology in treating eye diseases and conditions.

Company Overview

Operating in 70 countries and serving patients in over 140 countries, the company prides itself on its comprehensive range of surgical and vision care products. With a robust research and development (R&D) focus, the organization has a legacy of launching groundbreaking products that set industry standards.

Challenges in Product Development

Despite its success, the company faces several challenges expected in the medical devices sector:

• Complex Product Design: Eye-care devices require intricate designs due to the complexity of the eye as a sensory organ.
• Time Constraints: Aggressive development milestones often limit the time available for manual design checks for manufacturability (DFM) issues.
• Knowledge Management: The retention and dissemination of tacit knowledge among engineers present challenges, particularly for new hires transitioning from other industries.

The Need for DFM Automation

Importance of DFM

DFM is critical for reducing costs, improving product safety and efficacy, and ensuring timely product launches. Challenges associated with traditional DFM approaches include:

• Time-Consuming Manual Reviews: Identifying DFM issues manually is labor-intensive and inefficient.
• Knowledge Gaps: Accessing relevant DFM guidelines can be difficult, leading to inconsistencies in product quality.

Vision for Improvement

To streamline product development, the company sought to automate the DFM process within its existing design framework. This automation would enable designers to detect issues early in the design phase, reducing time and costs while improving product quality.

Implementation of DFMPro with Creo

Integrating DFMPro

Integrating DFMPro as an add-on to the Creo platform was a pivotal step toward enhancing the design process. DFMPro automates DFM checks and provides real-time recommendations based on the company’s guidelines, allowing engineers to make informed design decisions quickly.

Features and Benefits

• • Design Advisor: DFMPro acts as a design advisor, offering recommendations while modeling, thus minimizing manual checks.
  • Real-Time Guidelines: Company-specific guidelines are accessible and can be updated in real-time, ensuring all engineers have the latest information.
  • Traceability: Integration with Windchill enables robust DFM traceability, facilitating better collaboration across cross-functional teams.

Streamlined Workflow

Engineers can analyze designs directly within Creo, utilizing DFMPro’ s capabilities to check for compliance with design guidelines. This includes:

• Evaluating critical parameters, such as wall thickness and draft angles.
• Generating comprehensive reports that summarize findings and recommendations for design reviews.

Results and Impact

Enhanced Efficiency

The adoption of DFMPro led to significant time savings during the design process. Engineers can now detect DFM issues early, substantially reducing the need for costly revisions during production.

Cost Reduction

By minimizing engineering changes and rework, the company has experienced a direct positive impact on its bottom line. Faster design cycles also contribute to timely product launches, mitigating risks associated with lost market share.

Improved Collaboration

The centralized platform for DFM guidelines enhances knowledge sharing across the organization, ensuring that seasoned engineers and new hires can access essential information and best practices.

Conclusion

The integration of DFMPro with the CREO platform has transformed the product development process at the leading US-based medical devices company. By automating DFM checks and providing real-time recommendations, the company has enhanced its design capabilities, reduced costs, and improved overall product quality. As a result, the organization is better positioned to continue its legacy of innovation in the eye-care industry. Moving forward, the company plans to leverage DFMPro’ s capabilities to further streamline processes and maintain its market leadership.