Overview:
Medtronic Puerto Rico, a leading medical device manufacturer with a workforce of 1,500 employees, operates a state-of-the-art production facility specializing in manufacturing aids, jigs, fixtures, and molds. One of their critical components, a mold tip, was being produced at a scale of 400 parts per day using traditional injection molding.
Challenge:
The high cost and time associated with traditional injection molding processes. The production of 100,000 mold tips annually incurred significant expenses, with an estimated cost of $1.25 per part.
Objectives:
1. Cost Reduction: Achieve substantial cost savings in the production of mold tips, currently amounting to over $125,000 annually.
2. Improved Efficiency: Streamline production processes to reduce iteration time, enhance production speed, and minimize operational complexities.
3. In-House Production: Transition from outsourcing machining services for specific components, including three high-cost parts and an assembly aid, to in-house production for increased cost-effectiveness.
B9Creations' Micro 3D Printer Solution:
To address these challenges and achieve their objectives, Medtronic Puerto Rico adopted B9Creations' micro 3D printer, the B9 Elite Micro.
“Our facility is saving $120,000 a year by switching from injection molding to a B9Creations 3D printer.”
Total Production Capacity: 400 Parts per Day / ~100,000 Parts per Year
Product Iteration Time:
- Previous (Outsourced Injection Molding): 2-6 Weeks
- Now (B9Creations Micro 3D Printer): 1 Day (100 Parts Print in < 1 Hour)
Production Time:
- Previous (Outsourced Injection Molding): 10 Seconds/Part
- Now (B9Creations Micro 3D Printer): 36 Seconds/Part
Operations:
- Previous (Outsourced Injection Molding): New Tool for Each Part Iteration, Machine Program for Each Iteration/Production Difference
- Now (B9Creations Micro 3D Printer): New CAD File, Same Fast Print Time
Cost:
- Previous (Outsourced Injection Molding): $1.25/Part, $125,000 Annually
- Now (B9Creations Micro 3D Printer): $0.002/Part, $200 Annually ($8-12K Monthly Savings, $120K+ Annual Savings)
“We have three more parts we will be saving $20,000 per PO and an assembly aid we use daily that will save us $30,000 per PO by leveraging B9Creations technology.”
Results:
- Medtronic Puerto Rico now experiences monthly savings of $8-12K, translating to annual savings of over $120,000.
- Three additional parts that were previously outsourced at $20,000 per purchase order are now produced in-house for a fraction of the cost.
- An assembly aid used daily is expected to yield $30,000 in savings per purchase order.