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Hippocrates, famous for the Hippocratic Oath, urged doctors “namely to do good or to do no harm.” This admonition—routinely paraphrased as “first do no harm”—is also a good adage for medical device manufacturers to keep in mind, as the practice of medicine relies more than ever on the devices they make. But while most medical device manufacturers are careful to ensure that their products are safe and reliable, they don’t always give medical device packaging the same careful attention.

That oversight can have serious, even fatal, consequences.

7 Common Mistakes in Medical Device Packaging

There are two main purposes for medical device packaging: protecting a product so that it arrives intact and in good working order, and maintaining a sterile environment. Contamination is an especially urgent concern. According to the U.S. National Library of Medicine, viral and bacterial infections are among the ten leading causes of morbidity and mortality in the United States.

One way to prevent contamination—and the subsequent recall—of medical devices is with reliable, high-performance packaging. According to the U.S. Food and Drug Administration (FDA), packaging and labeling issues account for 13% of all medical device recalls, which is why some experts assert that medical device packaging is nearly as important as the device itself.

According to the U.S. Food and Drug Administration (FDA), packaging and labeling issues account for 13% of all medical device recalls, which is why some experts assert that medical device packaging is nearly as important as the device itself.

Now more than ever, healthcare organizations are working hard to reduce the number of hospital-acquired infections. And to help their customers achieve these goals, savvy medical device manufacturers have learned how to avoid the seven most common packaging pitfalls.

Mistake #1: Losing Sterile Integrity

Ensuring the sterility of medical devices is critical for reducing infection, yet it is the most common defect found in medical device packaging. Unfortunately, some medical device manufacturers fail to create a truly sterile barrier system (SBS) in which to encase their products for transport. This means that in some cases, when their products arrive at the point of use, they fail to meet the aseptic standards required by FDA and International Organization for Standardization (ISO) regulations.

While nonsterile packaging can be the result of contamination at the packaging site, often the issue is more fundamental—the design of the packaging itself. It’s important to keep in mind that packaging can only be made sterile on the inside. A package’s exterior will always arrive at its destination in a nonsterile state. This means it’s essential to design packaging that can be opened without introducing contamination.

So, how can you design your package to limit contamination? The National Library of Medicine found that pouches that had outward-curling seals had significantly lower contamination rates. In other words, if the exterior of a package curled away from the interior as the package was opened, it was far less likely that the outside of the package (the nonsterile surface) would come in contact with the interior’s sterile contents.

Mistake #2: Not Accounting for the Device’s Entire Journey

A sterile barrier system is only useful if it stays intact for its entire journey, which is why your package design must include protective material to shield the SBS from the time of assembly to the point of use. Many sterile packages are damaged due to pinholes, slits, cuts, and tears. To avoid these outcomes, wise manufacturers design an entire packaging system that protects the device—and its SBS—throughout the journey from factory to hospital. This means designing resilient packaging that can withstand exposure to road vibration during long hours of transportation. Packaging must also be strong enough to survive warehouse mishaps like a fall to the ground.

Mistake #3: Ignoring Best Practices for Medical Device Packaging

A medical device wrapped in a sterile pouch, part of a sterile barrier system
To keep your product free of contaminants, avoid folding, wrinkling, or creasing the sterile pouch.

Whether you’re shipping something as simple as a box of bandages or as complex and delicate as a tracheotome, your packaging is critical. Both the United States and Europe have stringent regulations for medical device packaging. Yet not all manufacturers adhere to best practices and regulations when it comes to certain aspects of their product packaging.

Some manufacturers, for example, fail to get their medical device packaging properly validated. It’s true that validation is an extensive and at times complex process. But the regulations serve a purpose. Rigorously testing your proposed packaging will ensure that it provides an effective barrier against microbial ingress, moisture, and environmental contaminants. Furthermore, a good validation process does more than ensure your packaging meets regulatory requirements. It also guarantees that your device gets to your customer in sterile condition, able to perform as advertised right out of the box. This preserves your brand reputation, and eliminates liability headaches as well.

Of course, your efforts to comply with FDA and ISO regulations can be negated if your product is contaminated by a vendor. So, if you’re working with third-party contractors, be sure to screen them carefully to ensure they’re also adhering to best practices for medical device packaging and shipping.

Mistake #4: Using the Wrong Packaging Material

Many medical devices are packaged using thermoform trays—plastic trays that are made by heating plastic sheets and molding them into the desired tray shape. But there is a wide range of plastic available for this purpose, and choosing the wrong one can lead to packaging failure. For example, if you’re packaging a medical device with a lot of mass, you might need a high-impact plastic such as polycarbonate to reduce fracturing during distribution and handling.

The design of the thermoform tray is also critical. The tray or case must be tight enough to hold the medical device firmly in place. Otherwise, a loose product could jettison through the tray lid and fracture the plastic casing from the inside out. Conversely, packaging must have a bit of give, so that it doesn’t damage sensitive sensors or other high-tech components. A good package design strikes the right balance between these two extremes.

Mistake #5: Using the Wrong Container

In addition to using the right packaging material, you need to choose the right size and strength for your exterior shipping box. For example, if you are using an outer carton to protect your sterile pouch, you need to avoid squeezing the pouch into a too-small carton. You should choose a container that avoids any folding, wrinkling, or creasing of the ends of your sterile pouch. Otherwise, the vibrations of a moving truck could lead to pinholes at the junctures of the creases or folds of the pouch. Complex pouch folds are even more problematic, as they form a concentrated point of stress at the juncture of the materials.

When it comes to the sterile pouches themselves, however, bigger isn’t always better. Some research has found that increased contamination rates are associated with larger pouches versus smaller ones. Unfortunately, the reason for this is not entirely clear. One theory is that larger pouches require more hands-on repositioning to open, and that this increased handling offers more opportunities for contamination.

Product trays should hug—not squeeze—the items they were molded to protect.

Mistake #6: Inadequate Testing

Just as it’s important to test and inspect your product, you need to test the effectiveness of your packaging material—and package design—to ensure that the SBS and the outer carton will protect the device as it travels from assembly to customer to storage.

Testing might reveal, for example, that a single sterile barrier is not sufficient to maintain a sterile environment for a product that might sit in a hospital storeroom for up to a year; instead, a double barrier is needed. Real-time aging testing like this will enable you to see how your medical device packaging holds up under storage conditions in which both temperature and humidity can fluctuate widely, especially over an extended period of time.

But what if you’re trying to beat a competitor to market? Or more importantly, get a life-saving medical device to patients as quickly as possible? That’s where testing via accelerated aging—elevating temperatures to artificially speed up the aging process—can be useful. For example, subjecting a sterile barrier system to 40 days of +55°C temperatures has roughly the same effect as storing the SBS at +23°C for a year. That’s a huge time savings.

There is a caveat, however. Using temperatures that are too high—in the hopes of cutting a few more days off the testing process—can cause a package to melt or warp in a way it never would under real-world conditions, negating the purpose of the test. So, exercise caution when applying accelerated aging techniques. Or work with a laboratory that specializes in testing via accelerated aging.

Mistake #7: Neglecting to Develop a Recall Protocol

In addition to protocols for testing, manufacturers should develop specific protocols in case the need for a recall arises. Such a protocol might involve plans for recall initiation, reporting, execution, and monitoring. Recall protocols are especially important right now, as medical device recalls are on the rise. Between 2012 and 2022, recalls increased by 125%. (And medical device adverse event reports increased by over 500%.)

Having protocols in place means you’ll be better prepared to initiate a voluntary recall, which will do less damage to your business reputation than a forced recall. That was the case for medical manufacturer Nurse Assist, LLC. In November 2023, the company issued a voluntary recall on its saline and other water-based products over concerns of compromised sterility. These included various bottles, spray cans, cups, and syringes. When the recall was initially released in November 2023, no adverse effects had been reported. And while the FDA has since received reports of adverse events, Nurse Assist’s prompt, voluntary action has enabled the company to mute the damage to its brand.

Diligence is Needed in Medical Device Packaging

As healthcare providers continue to prioritize infection reduction, and medical device recalls continue to rise, designing and deploying effective medical device packaging is more important than ever. Avoiding the seven pitfalls outlined here is the first step in making sure that your packaging performs in a way that increases patient safety—and enhances your company’s reputation.

A Packaging Partner You Can Rely On

Are you looking for a medical device manufacturing and logistics partner you can count on? At PRIDE Industries, our trained engineers can customize a turnkey manufacturing solution for your unique product. And our specialized knowledge doesn’t stop there. We’re also experts in medical device packaging, warehousing, and shipping. Discover what PRIDE Industries can do for you.
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There’s no question that computing advances like artificial intelligence (AI), big data analytics, and the internet of things (IoT) have had a big impact on electronics manufacturing. These and related technologies have enabled manufacturers to streamline design and production, as well as tighten the supply chain through greater integration with suppliers and improved communication with customers. But these new technologies have also introduced new manufacturing cybersecurity risks. A 2024 report by ABI Research and Palo Alto Networks found that 25.7% of industrial enterprises have experienced shutdowns due to cyberattacks. And according to Statista, over a quarter of detected cyberattacks in 2023 were against manufacturing firms.

Of course, the answer isn’t to go back to the days of fax machines and proprietary data systems. But to make sure that the latest cyber technologies work for you, it’s important to take steps to safeguard your systems and your data—especially from malicious actors.

Why Cybercriminals Target Manufacturers

Today’s cybercriminals are sophisticated, often able to adopt the personas of co-workers to ask what appear to be routine, work-related questions in order to obtain sensitive information.

Many people assume that finance-related firms are a higher target for cybercriminals than manufacturers. But that’s not the case. The manufacturing industry has over 40% more attacks than the finance or insurance industries, according to Statista. And ABI/Palo Alto has found that 70% of industrial organizations experienced cyberattacks in 2023.

So, what makes electronics manufacturers such a prime target?

One reason electronics manufacturers are attractive to cybercriminals is their large repositories of valuable data. Manufacturers often have extensive databases filled with personal information. That’s a virtual gold mine for hackers, who can sell that data to unscrupulous third parties for a large profit. Manufacturers also have valuable trade secrets and other proprietary information that make them a tempting target for ransomware attacks.

Cautionary Tales

A number of manufacturing companies have been targeted for ransom in recent years. The 2020 ransomware attack against Foxconn may be the most famous of these cyberattacks. In that breach, cybercriminals infiltrated Foxconn’s data systems and demanded a ransom of over $34 million in Bitcoin to prevent the release of sensitive data. And in June of that same year, Honda was hit by a cyberattack that took manufacturing plants in Ohio and Turkey offline.

A 2023 cyberattack on consumer products giant Clorox took many of its automated systems offline, including systems used by the likes of Walmart and Target to order products, costing the company $356 million.

As these examples illustrate, the damage from a successful cyberattack can cost hundreds of millions of dollars—making cybersecurity a paramount concern.

Multiple stacks of American money sit on a white table
In 2020, cybercriminals infiltrated Foxconn’s IT systems and demanded $34 million to prevent the release of sensitive data.

Two Factors Contributing to Manufacturing Cybersecurity Risk

Hackers have been around as long as there have been systems to hack. However, recent advances in technology, coupled with the global pandemic in 2020, set the stage for a rapid escalation of cybercriminal activity.

When the pandemic first hit, there was a mass movement of workers from onsite offices to less-secure remote workspaces—a cybercriminal’s dream. Companies now found themselves vulnerable and ill-prepared for a shift that came on suddenly and had exponential growth. Few companies had robust plans that accounted for the specific security requirements of offsite work. Cybercriminals quickly took advantage of the situation, and ransomware demands skyrocketed. According to the Harvard Business Review, in 2020, the ransom amount paid to cybercriminals increased by more than 300%.

Another challenge to manufacturing cybersecurity is the introduction of more technology into the manufacturing process. While advances such as industrial robots and artificial intelligence can increase productivity and improve supply chain management, these technologies can likewise increase security risks. For example, the rise in connected devices within a manufacturing facility has given cybercriminals new points of attack. Now, if criminals can locate a vulnerability in one area, they potentially have access to a company’s entire interconnected landscape.

Five Ways to Enhance Your Manufacturing Cybersecurity

Cybercriminal activity has caught the attention of the U.S. government, which is trying to increase manufacturing cybersecurity by bringing chip production back home. The 2022 CHIPs and Science Act, for example, requires all semiconductor manufacturing facilities to be located in the United States in order to qualify for funding. The assumption is that facility-wide sabotage will be harder to conduct under U.S. laws and the watchful eye of U.S. counterintelligence officers.

The duty to combat cybercriminals, however, is not solely a government responsibility. There are many steps that companies can take to increase their own manufacturing cybersecurity.

1. Implement Zero Trust Architecture

A graphic skull composed of zeroes and ones superimposed over a green computer display
The manufacturing industry experiences 40% more cyberattacks than the finance or insurance industries.

Zero trust architecture (ZTA) is a security framework based on a simple concept: Don’t automatically trust any user or device, regardless of their location or network.

This strict approach to cybersecurity came about a couple of decades ago. At the time, the standard security model was based on a hardened perimeter around a corporate intranet. While there were protocols in place to ensure that only trusted users gained access to company systems, once inside a company’s online environment, a user could roam freely. This model worked well for a time, back when work was contained in a physical office building and employee devices were limited. But it proved ineffective once remote work became common. And even before the explosion of connected personal devices—i.e., tablets, smartwatches, and mobile phones—cybersecurity experts were getting worried.

One of the pioneers in solving the interconnected-device problem was John Kindervag, considered one of the world’s foremost cybersecurity experts. In 2009, he coined the term “zero trust model.” Its foundational principle comes from a Russian proverb—”trust but verify”—and it’s proven to be solid advice for many organizations. If you want to ramp up your company’s cybersecurity, be sure to adopt all three components of a zero trust model:

  • Ensure all resources are accessed securely regardless of location.
  • Adopt a least-privilege strategy and strictly enforce access control.
  • Inspect and log all traffic.

Many companies now employ this guilty-until-proven-innocent approach across functions and departments. Most employees encounter the zero trust model whenever they’re asked to engage in multifactor authentication (MFA), which requires users to verify their identity at least twice to gain access to systems. In fact, MFA is one of the simplest ways to safeguard against cybercriminals, and even small to midsized manufacturers can easily implement this protocol.

2. Go Beyond Information Security

A cyber-physical system is a one that integrates sensing, computation, control, and networking between physical objects and infrastructure—connecting objects to the internet and to each other. An example of a cyber-physical system would be driverless cars that communicate securely with each other on smart roads.

The increased connectivity among engineered systems is bringing more risk than just information theft—it also introduces the possibility of harm to humans and the environment. Case in point: AP News reported in 2021 that someone attempted to poison a water treatment plant in Oldmar, Florida. Using a remote-access system, the hacker tried to increase the level of lye in the water supply to a dangerous level. The attempt was fortunately caught by an astute supervisor, and the city has since disabled the remote-access system.

Because of these types of risks, Gartner advises companies to take appropriate precautions, pointing out that CEOs could potentially be held personally liable for cybersecurity incidents. “In operational environments, security and risk management leaders should be more concerned about real world hazards to humans and the environment, rather than information theft,” a Gartner researcher said in 2023.

3. Create an Incident Response Plan

Even the most secure systems face risk. The question is not “if” your company will be targeted but “when.” Therefore, every company should create a thorough incident response plan: a set of written instructions with clear details on what to do in case of a data breach or other cybersecurity incident. And the time to plan is beforehand—not after an attack when every minute is critical to containing the breach. With emergency protocols and backup systems in place, you won’t waste valuable time figuring out the best response or obtaining the necessary permission to act.

Gartner suggests that an incident response plan have four phases:

  • Preparation
  • Detection and Analysis
  • Containment
  • Eradication and Recovery

Putting a response team in place and creating a plan can seem overwhelming, but it’s important to recognize the journey towards security is an evolution. As Andy Ellis, former CISO at Akamai, has pointed out, “You don’t have to do it all at once.” The focus should be on having a well-thought, actionable plan, and implementing it step by step over months, or even years if that’s what’s required.

4. Provide Employee Education and Training

Imagine pouring millions of dollars into your cybersecurity systems, only to suffer a breach when an employee unknowingly responds to a phishing email. Unfortunately, many employees still associate “phishing” with obvious scams involving foreign princes. But today’s cybercriminals are far more sophisticated, often able to adopt the personas of co-workers to ask what appear to be routine, work-related questions in order to obtain sensitive information.

While you can’t eliminate all risk of user error, proper instruction and training on cybersecurity best practices will go a long way in decreasing your company’s cybersecurity risk. And this training must be repeated on a regular basis. For example, don’t just teach employees how to identify phishing emails; send fake emails on a regular basis to test employee responses. For those who fall victim to the bait, additional training and support should be offered. Other best practices, such as requiring a second type of confirmation for sensitive requests, can also increase security.

5. Choose Your Third-Party Contractors Wisely

No matter how locked-down your own systems are, you’re only as secure as your third-party vendors and contractors—a fact exemplified by the infamous Target breach that affected 41 million consumers. Initially, no one knew how the breach occurred, but it was later discovered the hackers accessed the Target gateway server by stealing credentials from a third-party vendor.

Lesson learned? Be diligent in your screening of third-party contractors. The security of your supply chain is just as important as your internal cybersecurity.

Manufacturers in certain industries must be especially diligent. As cybersecurity company Palo Alto Networks has pointed out, “manufacturers that build national security-related products face additional types of cyber threat actors and thereby additional urgency to protect their sensitive data.” For these manufacturers, it is especially important to do business with reputable third parties that have the proper registrations and compliance programs in place. For instance, a manufacturer of defense technology should verify that its contract manufacturers are ITAR registered and have appropriate internal controls in place to secure sensitive products and all the technical data associated with such products.

Another industry that requires enhanced security is medical device manufacturing, which is why the U.S. government is attempting to increase security in this area. With the passage of The Consolidated Appropriations Act of 2023, the FDA is now required to include cybersecurity as part of its review for medical devices that contain software, such as heart defibrillators and continuous glucose monitors (CGMs).

No matter your industry, it’s not enough for your own data to be strongly encrypted. So don’t just monitor your own systems—protect your supply chain by ensuring that your vendors are doing the same.

Putting Manufacturing Cybersecurity at the Forefront

According to Forbes, the operational technology (OT) and industrial control systems (ICS) of manufacturers have traditionally focused on speed and efficiency, while cybersecurity has taken a back seat. And unfortunately, a lot of manufacturers still rely on legacy systems and outdated practices that are ill-equipped to handle today’s cybersecurity threats. If this describes your business, then now is the time to act in order to avoid becoming another cybersecurity cautionary tale. The five steps outlined above are a good way to start.

A Secure Manufacturing Partner

At PRIDE Industries, we provide the highest levels of security, structure, quality, and expertise. We are ISO 9001 and ISO 13485 certified, ITAR registered, and have SMTPE-certified engineers on staff. Our customers know they can rely on us to keep their proprietary information secure and their supply chain protected.
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Our Director Of Product Engagement, Andrew Williams, talks with electronics manufacturing publication EMS Now Publisher Eric Miscoll about how award-winning, state-of-the-art electronics manufacturing and employing people with disabilities go hand-in-hand in this video interview.

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In 1954, the first robotics patent was filed by George Devol, affectionately known as the “grandfather of robotics.” In 1956, together with Joseph Engleberger, Devol founded the first robotics company, Unimation. Five years later, Unimation’s first robot—aptly named Unimate—was installed at a GM plant where it was programmed to retrieve and stack hot die-cast metal pieces, saving human workers from the risk of burns. Soon, Unimation expanded to include industrial robots that could print, weld, and assemble.  

Devol’s patent for a programmable robotic arm became the foundation of our modern robotics industry. Today, according to the International Federation of Robotics, there are approximately 3.9 million industrial robots worldwide. Statista estimates that the global robotics industry will hit $43.32 billion in revenue in 2027, compared to just $18.47 billion in 2016.

The Benefits of Industrial Robots in Electronics Manufacturing

Current trends point to electronics manufacturing becoming the largest market for industrial and collaborative robots in the near future.

The demand for industrial robots is rising in many industries, including electronics manufacturing, which currently accounts for 22% of total robot shipments. This is second only to the automotive industry, which accounts for 33%, according to Supplyframe. But while the automotive industry has been the major consumer of industrial robots for a long time, Supplyframe reports that current trends point to electronics manufacturing becoming the largest market for industrial and collaborative robots in the near future. This development is not surprising, as industrial robots offer electronics manufacturers a host of advantages.

Ability to Tackle Complex or Delicate Tasks

As components and circuits continue to shrink, and component density rises, human technicians are encountering physical limitations. Automated robots, on the other hand, support miniaturization. They can build connectors, subassemblies, display screens, and more—safely handling electronic components of any size. Robots equipped with force and tactile sensors, for example, can place even delicate components precisely and quickly, speeding up the coating and assembly of PCBAs and finished products.

Accuracy and Speed

For the moment, humans are still able to navigate the challenges of miniaturization, component fragility, and task-to-task variability. But they are often no match for robots when it comes to speed in assembly and testing. Humans are also more likely to introduce errors, waste, and inefficiencies. Industrial robots equipped with sophisticated imaging technology and AI software, on the other hand, can efficiently perform both inspection and pick-and-place operations with an extremely low error rate.

Consistency and Dependability 

Unlike humans, industrial robots can repeat the same task over and over without getting tired, taking a break, or making a mistake. They can also work beyond an eight-hour shift with no overtime pay required. Industrial robots are also more consistent, able to perform the same function over and over without variation—producing thousands of PCBAs, for example, that are identical.

A close-up view of a robotic flying probe hovering over a printed circuit board assembly
Flying probe testing uses programmable robotic probes that move over the surface of the PCBA, contacting test points, components, and traces.

Flexibility

Modern robots aren’t just more precise than their predecessors—they’re also more adaptable. Today’s robotic arms are flexible and lightweight, and can easily adapt to multiple applications, saving manufacturers both time and space. When product designs change, smart robots don’t require replacing; reprogramming and swapping out a few parts, such as an arm attachment, is often all that’s required.

Workplace Safety

Workers can also benefit from automation, especially when it comes to workplace safety. Electronics manufacturing involves the use of numerous potentially hazardous heavy metals and other materials. Robots can help reduce workers’ exposure to these materials by taking over coating and other tasks that require the use of chemicals. And when it comes to assembling the finished product, robots can also eliminate the need for workers to repeat ergonomically problematic movements.

Cost  

Many steps in electronics production—including component fabrication, PCBA assembly, adhesive application, inspections, packing, etc.—are repetitive tasks. This makes them ideal for automation. Using robots to perform these functions doesn’t just save on labor costs; it also reduces the errors that lead to costly manufacturing waste.

Three Trends in Industrial Robotics

Human inefficiencies have a cost. So, an automated solution that can simultaneously improve product quality while lowering overall unit cost is a boon to manufacturers. In many cases, industrial robots provide that solution.

Electronics manufacturers are recognizing these benefits. In a survey of industry leaders by trend-spotting company Exploding Topics, 97% listed improved product quality as a clear benefit. Additionally, 95% mentioned faster production speeds, and 92% cited greater production capacity.

Around the world, companies are embracing automation. In fact, McKinsey & Company reports that many companies will dedicate 25% of their capital spending over the next few years to automated systems, with the goal of improving output quality, efficiency, and uptime. This global trend in robotics adoption is due to the expanding capabilities of today’s industrial robots, which are being fueled by three major technological advances.

The head and shoulders of a humanoid robot with a metal-and-silicone face
Some new robots have a more accessible, humanoid appearance.

Machine Learning and Artificial Intelligence (AI)

Sometimes the terms “AI” and “robotics” are used interchangeably, but they are two different technologies. Robotics is the science of designing and building physical robots to perform automation. AI, on the other hand, focuses on how to create machines and technology that mimic human intellectual capabilities.

The two worlds, however, have a lot of overlap. Some robots now allow users to program them using natural language instead of code. This advance is a big one, as it removes the need for workers with specialized programming skills. And in some cases, the need for humans is even further reduced. It’s possible to build a factory that’s so automated that a human need enter the premises only once every few weeks. Known as “lights-out manufacturing,” this approach to production is nearly fully automatic. For example, FANUC, a Japanese robotics company, operates a factory where robots can run unsupervised for up to 30 days at a time.

Cobots

Have you ever felt like you could use an extra pair of hands to perform a task? A cobot, also known as a collaborative robot, provides that option. Cobots are designed to work alongside humans and are one of the fastest-growing segments of the industry. They are especially useful for small companies that cannot afford or do not want to deploy a fully integrated robotic system.

Mobile Manipulators

Mobile manipulators—also known as “MoMas”—combine the mobility of robotic platforms with the dexterity of manipulator arms. The mobile platform extends the workspace of the arm, while the arm itself offers the necessary functional operations. Using cameras and sensors, these robots can perform maintenance tasks and inspections on equipment.

With their ability to support human workers, MoMas are being used across a large spectrum of industries. For example, in the aerospace and defense sector, they can perform such tasks as aircraft assembly, inspection, and maintenance. Some of their benefits in this sector include the ability to handle delicate components, maneuver in confined spaces, and perform precise operations.

MoMas are also bringing further automation to the car industry. As automotive electronics become increasingly sophisticated, car manufacturers are looking for ways to be more efficient. Mobile manipulators are ideally suited for such tasks as assembly, transport of components, and quality checks. Using this advanced technology, car manufacturers can improve product quality as well as production speed.

Given their myriad applications, and the ongoing labor shortage, it’s no surprise that MoMas are gaining in popularity across these and other industries.

When Not to Use Industrial Robots

While industrial robots bring many benefits, there are situations in which companies would be wise to think twice before investing in this capital-intensive technology. Here are a few caveats to keep in mind.

Cost

While industrial robots can certainly save money in the right situations, just the opposite is true in some cases. Companies, therefore, need to perform their due diligence by conducting a cost-benefit analysis. Humans can be less expensive—and reliable enough to produce a high-quality product. The fact is, installing industrial robots entails a high capital outlay. And in some cases, a cost-benefit analysis will reveal that the return on investment does not justify the expense incurred. In these cases, it’s good to keep in mind that there are other ways to save time and money in electronics manufacturing.

Complexity

A lack of experience with automation can pose a significant hurdle for many companies, especially those that are small or mid-sized. Even if you have the capital to install the system, do you have personnel with the expertise to operate and maintain such a system? While generally enthusiastic, McKinsey found several concerns about the adoption of industrial robots, including how to fit the machines into existing spaces, and the ability of the robots to interface with existing production processes.

Cybersecurity Risks 

Stories of cyberattacks, across multiple industries, are plentiful in the news today, leading to widespread concern about automation and the misuse of AI. According to the AIAAIC, the number of AI incidents and controversies recorded in its database is now 26 times greater than it was in 2012. And companies have noticed—McKinsey found that cybersecurity concerns sometimes deter manufacturers from the use of robotics.

Should You Invest in Industrial Robots?

So how does a manufacturer decide whether or not to pursue industrial robots as part of their manufacturing plan? As with so many things, it depends on your company’s unique situation. For some manufacturers, a more hands-on approach will be optimal. Depending on the manufacturing steps, humans may be able to move more efficiently from one task to another than robots that require refitting or reprogramming. If you manufacture a broad range of products, would automating your factory floor require a plethora of specialized robots?

It can take a lot to figure out the right balance between robots and humans. Fortunately, you may not need to decide. One way to keep it simple—and avoid a high capital outlay—is to hire a contract manufacturer who has already figured out how to get the job done in the most efficient and cost-effective way.

Reliable Electronics Manufacturing

Are you looking for a contract manufacturer that you can count on? Our in-house design team, certified engineers, and dependable workforce mean that you can receive all the benefits of automation and skilled labor—without unnecessary capital outlays.
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It’s no secret that artificial intelligence (AI) and machine learning are infiltrating the way we do business—as well as our personal lives—in multiple ways. Uber uses AI to forecast the number of ride requests for different locations. Social media platforms customize user content by applying AI algorithms. And manufacturers across a variety of industries are using AI to take predictive maintenance to a new level, analyzing historical and real time data to anticipate failures and repair or replace machinery before something breaks. So it’s no surprise that electronics manufacturers have found yet another use for AI: optimizing electronics packaging.

The global market for AI-facilitated packaging is expected to grow at a compound annual growth rate (CAGR) of 55.2 percent from 2021 to 2026, according to Global Market Estimates, a market research and consulting company. This rapid increase in the use of AI to optimize packaging is no surprise, as improved packaging offers many benefits, from better product protection to improved brand positioning.

Because electronic devices tend to be fragile and prone to damage during transit, AI can be especially useful in optimizing their packaging.

Important Considerations in Electronics Packaging

Because electronic devices tend to be fragile and prone to damage during transit, packaging must be optimized for specific products. So how does an electronics manufacturer choose the best packaging? Opting for the cheapest solution doesn’t always save money in the long run. Manufacturers have many factors to balance and questions to consider, including:

  • How well will the packaging protect the product?
  • Does stronger packaging justify a heavier weight and higher shipping costs?
  • Is there an acceptable level of returns for damaged products? If so, what is it?
  • What is the optimal balance between packaging price and performance?

In addition to the questions above, manufacturers need to think about customer perceptions, as people are becoming more concerned about packaging pollution. In a 2020 survey, McKinsey & Company found that 60 to 70 percent of consumers said they would pay more for sustainable packaging. AI can be used to analyze vast stores of internal and public data to optimize packaging so that it meets electronics manufacturers’ requirements for quality, safety, and sustainability, allowing them to quickly find the right balance between cost and effectiveness.

3 Ways AI is Improving Electronics Packaging

Successful electronics manufacturers are constantly evaluating new technologies and seeking ways to improve production. Across the nation, these savvy manufacturers are leveraging AI and machine learning to optimize their product packaging in three critical areas.

Design

AI can help companies optimize electronics packaging by analyzing data such as product type, weight, and fragility. It can also factor in other considerations such as company sustainability goals and shipping distance. AI can even be used to incorporate packaging considerations into the product design phase, helping engineers configure a product that costs less to ship and is more resilient in transit, resulting in fewer returns.

AI algorithms are now being used to customize packaging for a broad range of products. A TV, for example, may require a box with thicker corners for better edge protection. Other electronics packaging considerations include protection from falls, extreme temperature, vibration, humidity, sunlight, contamination, and water. To minimize vibration, containers sometimes include internal locking mechanisms. And to make product inspection easier, clear locking containers—such as those manufactured by U.S.-based Clamtainer—allow final inspection of a component without disturbing the packaging.

AI can also be used to determine the ideal packaging material for a particular product. This is especially important given the range of new materials available, which are far more diverse than traditional cardboard and polystyrene packing peanuts. Mushroom packaging, for example, is made from an organic material that’s literally grown to a precisely programmed shape using a process that takes just seven days. Other novel materials include bamboo, cornstarch, and seaweed—sustainable substances that win kudos from the general public, enhance a manufacturer’s reputation among consumers, and can even cost less than traditional packaging.

Another way that AI is impacting package design is by using 3D prototypes to speed up the time it takes to determine the optimal packaging for any given product. In the same way that 3D prototyping is used to test product designs, packaging options for the finished product can be tested and quickly modified using AI models and 3D printing technology—without the expense or time of producing the actual electronics packaging.

A packing container molded to fit an electronics device sits next to a large pile of mushrooms.
Mushroom packaging uses agricultural waste and mycelium to grow custom-shaped, break-resistant containers in as little as seven days.

Sustainability

Optimizing a product’s packaging should be part of any initial product design, especially if sustainability is important to your company—the European Commission estimates that more than 80 percent of all product-related environmental impacts are determined during the design phase. However, leveraging AI for sustainability goes beyond design. It can also help reduce waste, decrease shipment damage, and lower shipping costs. Amazon has been using an AI model that learns from real-world customer complaint data to accomplish these goals. Applying their machine learning model to hundreds of thousands of packages, they have been able to reduce waste, cut shipment damage by 24 percent, and reduce shipping costs by five percent.

AI can also help manufacturers design packaging with recycling in mind. This not only helps companies meet their environmental, social, and governance (ESG) objectives, it’s also becoming an essential objective now that more and more local governments are enacting extended producer responsibility (EPR) regulations. For example, California passed a law in 2022 that imposes new regulations and fees on manufacturers of single-use plastic packaging. Other states—including Maine, Oregon, and Colorado—have also passed strict EPR laws. And while many of these regulations primarily affect the makers of plastic forks, straws, and bags, they are expanding to include packaging for all kinds of products.

Supply Chain Management 

A man using plastic bubble wrap to cover a small cardboard box.
In some states, extended producer responsibility (EPR) requirements make plastic packaging an expensive option.

AI can also help in supply chain management, from production inspection to shipping improvements, enhancing or even replacing human efforts. Unlike a person, AI never gets bored or distracted—it doesn’t miss product defects. And unlike human brains, which have a tendency to fill in missing data and thus see things that aren’t there, an AI “brain” lacks this imagination, and so more accurately detects a product’s true state.  

AI can even improve on the traditional “machine vision” technologies that are used for inspections. Many current visual inspection technologies are capable of spotting variations from a programmed standard, but can’t determine if the variation is acceptable. For example, in the case of date labeling on a package, if a date is in a different font, many current inspection systems will reject it as an error. Harry Norman, founder of OAL, a British automation and robotics company, likens traditional machine vision to having vision without a brain. Incorporating AI into the system gives the machine a “brain,” one that can be trained to account for variation. For example, a date stamp with a tilted “2” that would have been rejected in the past with traditional visual inspection technology can now be recognized as acceptable.

Yet another way AI is strengthening the supply chain is by streamlining the shipping process. Manufacturers now have access to data-driven shipping automation platforms that include packing algorithms. According to ShipHawk, a U.S.-based provider of automated shipping solutions, companies can lower shipping-related costs by more than 20 percent with data-driven shipping. Machine learning algorithms can also be used to assign packages unique RFID tags so that products can be easily tracked throughout the entire supply chain.

Don’t Set It and Forget It

Keep in mind that AI is only as good as those who design, program, and monitor the technology. So be cautious about taking a hands-off approach. But with the right oversight, AI can transform electronics packaging. The technology’s ability to improve design, enable the use of novel materials, and make recycling easier means that manufacturers will undoubtedly continue to use AI to optimize their product packaging for years to come.

Kitting and Fulfillment Services with a Positive Social Impact

PRIDE Industries offers comprehensive packaging and fulfillment services that incorporate sustainability practices tailored to each customer’s needs. Our flexible approach, backed by a dependable and inclusive workforce, gives our customers both reliable service and a unique social marketing advantage.
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