Process Line Design and Build Support – Patented Vial Automation
The Challenge – Process Line Design
Client: Automation machine manufacturer
Objective: Accelerated mass production
In response to the government’s “warped speed” initiative to find a coronavirus vaccine, a custom automation company needed to develop a process line to mass produce vials that would be used to store the novel coronavirus (SARS-CoV-2) vaccines and therapeutics.
The process line used a patented Plasma Enhanced Chemical Vapor Depositing Technology to apply a barrier media to plastics. Because of the urgency of the COVID-19 response, the prototype/design/fabrication cycle needed to be accelerated to meet the demand of “Operation Warp Speed.”
- A custom automation and advanced materials company needed to co-develop a process line of multiple machine modules integrated with patented technology.
- Due to the accelerated schedule to produce vials, the custom automation company needed to engage a partner who could quickly collaborate with the co-development team to design and build a proof of concept prototype.
- After the prototype validation, a value engineering phase was required to reduce the system cost so that 13 automated process lines (~10 machine modules/process line) could be produced cost-effectively within the compressed schedule.
- The compressed design schedule also required daily design reviews and progress reporting to the customer.
- To deliver the 13 automated process lines, the client needed additional help with project management, purchasing, machine building, and assembly support.
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The Process Line Solution
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The client engaged Sterling Engineering to provide the expertise to develop next-generation designs and provide the workforce for scalability to bring these systems to market.
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