Mitsubishi Electric automates life science applications.

Mitsubishi Electric’s Factory Automation products are well established in processes from secondary packaging through to processing applications, and increasingly into life science applications.  For example by extending the use of robotics into surgical processes; controlling ozone sterilization for medical instruments and even in the production of replacement body parts such as replacement hip joints.

Improve productivity

Many production processes in today’s pharmaceutical and medical industries are based on old fashioned techniques and technologies, so cannot meet the constant challenge of increasing productivity. As well as rising demand, state of the art plant needs to be adaptable for changing requirements, compact for smaller production areas, and be able to quickly and efficiently generate a return on investment (ROI).

Mitsubishi Electric offers uniquely integrated technologies that combine robotics with discrete automation and precision motion, all functioning in harmony through a single controller called the Mitsubishi iQ Platform, or Platform for Life Science.

Improving profitability

Robots provide the greatest flexibility in today’s production environments. Their ease of programming, precision accuracy, compact size and high speed all combine to provide effective and efficient operation. Space-saving is an inherent attribute of robots – they can even be mounted on the ceiling of a cell, freeing up the whole production area below for applications such as syringe filling.

Mitsubishi’s robots are complemented by a wide range of automation equipment such as servomotors and motion controllers that integrate seamlessly into the iQ robot controller. Touch-screens (also called Human Machine Interfaces or HMls) are used to operate and reset the equipment.

All relevant production data can be collected in a single, secure database within the iQ. This automatically transfers the data to higher level control systems such as plant-wide Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) systems, for total automation.  This level of integration provides maximum productivity, quality and availability in a 24/7 production environment.

Regulations and quality

The advantages of integrated automation are best illustrated by some examples. Ampoule handling, for instance, requires high speed, high accuracy and complete traceability, while each ampoule has to be individually identifiable so that it can be correctly labelled.

A robot can collect ampoules from a filling head, transfer them to a filling-level test station, label each one accordingly, then place them in a tray. Ampoules that don’t meet the test criteria are removed automatically by the robot. The whole operation is an efficient single-stage process which ensures each ampoule meets the required regulations and quality standards, and that only perfect products proceed onto the packaging process.

Another example is the measurement of an artificial joint, were absolute accuracy is required when mating the two parts of the joint. In a manufacturing cell, a robot places the joint, measures it precise position in every plane. The outcome of the extensive set of tests in the cell is the condition to transfer the joint to the packaging station. Still within the cell an extensive set of tests is carried out on the joint before it is transferred to the packaging station. The test data is automatically and instantly logged in the iQ database and used to provide traceability records, print labels, and advance the production sequence. This process is entirely automated and can run in a 24/7 shift pattern.

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