Case Studies

Innovation means redefining industry standards, transforming iconic brands, and bringing new products, ideas, and methodologies to life through emerging technologies.

High-Volume Medical Production Line Installation & Validation

Our Class II medical device client needed to launch a new high-volume high-mix production line on a very short timeline. In addition, the line needed to meet strict FDA process guidelines. They lacked the resources and the experience in complex production line design, install, and validation to meet their tight deadline, while maintaining the quality standards required to receive FDA approval.

Problem/Challenge:

Our client needed to scale their production to meet market demand and wanted to take the opportunity to optimize the process as well. Key goals/challenges included:

  • High-mix product line
  • Very small form-factor
  • Complex cleanroom filling process
  • Multi-stage packaging process
  • Required FDA approval
  • Short timeline

Approach/Action:

QFocus assembled a team with the necessary expertise and tackled this project using a proven 5-step business approach. After performing a thorough analysis of the existing plant process and technology, the team proposed an optimized design, validated the new process and did a prototype demonstration, before implementing the line, testing, and final qualification and approval.

Impact/Results:

The QFocus team worked in close collaboration with our client and external authorities to expedite approvals and meet the launch deadline. The resulting production line delivered:

  • Increased capacity
  • Reduced cycle times
  • Reduced labor
  • 100% process validated state
  • FDA approved process

Quantitative/Qualitative Impact Statistic

Faster TTM

Higher Quality

Increased Margins