MicroPulse: Unmanned evening and night shifts in high-mix orthopedic production

With 11 RoboJob systems installed on lathes and milling machines, MicroPulse keeps its CNC machines running throughout the evening and night. A single operator manages multiple machines, downtime has decreased, and product quality has become more consistent.

“If you’re unsure about automating your workshop, go with the experts. RoboJob makes it easy for us to learn how to integrate their robots into our operations.” Bradley Emmerich, Director of Business Development, MicroPulse.

About MicroPulse

MicroPulse is a contract manufacturer dedicated entirely to the orthopedic industry. The company manufactures implants, instruments, cases, and trays, and provides sterile packaging for orthopedic implants, spinal components, and trauma implants.

The founder started out in 1988 in his garage, with an EDM machine that he brought home in the back of a pickup truck. Today, MicroPulse has grown into a manufacturing facility covering approximately 280,000 sq ft.

The challenge: Growing without enough staff for the late shift

After COVID, MicroPulse experienced strong, sustained growth. At the same time, it was difficult to find enough people for the second and third shifts, causing machines to come to a standstill in the evenings and at night.

Automation wasn’t entirely new: pallet changers had been in use at the company for more than 25 years. However, MicroPulse had little experience with machine-loading robots. The company didn’t have its own engineering team capable of programming a robot from scratch.

On top of that, medical contract manufacturing is typically high-mix, low-volume. A solution therefore had to be able to switch quickly between many different parts.

The Solution: Partner with RoboJob to Get Started with Automation

RoboJob helped MicroPulse take its first steps in machine loading. The team installed the systems, provided installation checklists, and trained the staff on how to use them, even though the company had no prior experience with them.

“RoboJob made it very easy for us to program our first parts on our milling machines.”

Designed for high-mix, low-volume production. Thanks to its user interface, MicroPulse makes it easy to program multiple parts, even on the same machine. After the initial setup, the operator can switch jobs on their own, without needing an engineer or a special team to step in.

“The interface is so intuitive that our operators can use it with confidence without extensive training.”

The RoboJob system works right away, but allows for customization. For example, Micropulse has customized the following:

- Custom-designed gripper fingers

- The suction cup function for certain parts

- Modified nesting

From 1 robot to 11

After the initial installation, it was easy to justify purchasing additional robots. In the months and years that followed, MicroPulse continued to add more; today, 11 RoboJob systems are running on lathes and milling machines.

More machine hours during the late shifts. One operator loads the pallets during the first shift. The robots then keep the CNC machines running during the second and third shifts, and the operator sets them up again in the morning for the next day.

One operator for four to five robots. The systems are set up so that one person can keep multiple units running.

Fewer downtimes, more consistent quality. Since the introduction of the RoboJob systems, the machines have produced less scrap. An unexpected bonus is that the quality of the finished parts is also noticeably more consistent. A positive result that wasn’t anticipated beforehand.

Lighter workload for the operators. They operate more machines and can rely on the robots to consistently produce high-quality parts.

No jobs lost, but greater efficiency. Automation has not cost a single job at MicroPulse. It allows people to operate more machines and focus on the work they do best.

“Automation is simply a tool for working more efficiently. It helps everyone become even more efficient at what they already do well.”

Advice for Those Who Are Unsure

Bradley recommends choosing a company that is flexible and very user-friendly, as well as a partner with expertise. It pays off even in an environment with many variants and small production runs.

“Our business runs on relationships, and we have an excellent relationship with RoboJob. Thanks to our RoboJobs, our people can continue to solve problems while the robots manufacture our parts.” — Bradley Emmerich, MicroPulse