Patchstar Micromanipulator
MY ROLE
Production Engineer.
Define the Problem, Measure, Analyse the Date, Action Improvements, Set Controls
OVERVIEW
Scientifica specialises in providing cutting-edge equipment optimised for electrophysiology, multiphoton imaging and optogenetics research.
The Patchstar Micromanipulator is the companies biggest seller and what they are best known for.
In-field faults and failures had been steadily increasing over the past 12 months without a known cause.
Management approved a full investigation. I used Six Sigma to determine the root cause, and provide deliverable actions and controls.
Hypothesis
The design of the patch star is highly sensitive to error in terms of manufacturing and assembly.
Null-Hypothesis
The design of patch star has created no issues in terms of manufacturing and assembly.
Analyse - Pareto
The Pareto Analysis of this data shows that the main issues are caused by only two factors -
Loose Stage
Loose Base
Improvements - Short Term
Change the grub screw used in the rotary base
WHY: Grub screw used to secure the base is a soft steel grade and plastic flat tipped. Easily damaged and does not bite and grip.
Change grub screw to A2 Stainless and a cone point tip
Current
Improved
Improvements - Medium Term
Conduct shipping trials to highlight packaging effectives and areas of risk
WHY: In-transit vibration and drops could all seriously damage what is a sensitive piece of scientific equipment.
Shock stickers to be implemented to identify damage during transit.
Improvements - Long Term
Patch Star Manipulator Version 2 with design for manufacture and design for assembly in mind.
WHY: : Product is 8 years old with no DFM or DFA. New materials / machining techniques could be employed to improve it.
An improved specification product could design out the current issues, increase reliability and lower manufacturing costs.
Control
Implemented actions to control and prevent future issues:
Production out-going product testing implemented.
Updated work instructions.
Production staff training matrix.
Annual training refreshers.
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