The Implementation of Robotic Automation for Syringe Filling - PowerPoint PPT Presentation

The Implementation of Robotic Automation for Syringe Filling Processes John Cutler, Perry Diamond, Wyatt Jones, Jorden Krueger, Jackson Payne Dr. Noble Anumbe, Dr. Ramy Harik, Jay Henderson, Kaishu Xia University of South Carolina May 31, 2019 For further information: harik@cec.sc.edu University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 1

USC Team Sr. Design Team Members: • John Cutler • Perry Diamond • Wyatt Jones • Jorden Krueger • Jackson Payne Faculty Advisor: Ramy Harik Scientific Support: Kaishu Xia Office of Academic Engagement: • Jay Henderson • Noble Anumbe Team Members University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 2

Outline I. Design Parameters II. Simulation of Process III. Equipment and Components University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 3

Design Parameters Section I University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 4

Design Parameters Automation Responsibilities: I Operators two and three will be fully automated. II ▪ Syringe Filling III ▪ Pump Actuation ▪ Syringe Capping ▪ Syringe Dispensing University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 5

Design Parameters Sterilization Parameters: I ▪ Opening of syringe packaging must take place within the ISO 5 hooded environment II ▪ Syringe tip must remain within the laminar flow at all times (preferably perpendicular III to the wall of airflow) ▪ The process must take place at a depth of 6 inches from the front of the hooded environment and six inches from the back of the hood ▪ Once capped , the syringe may be removed from the ISO 5 environment University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 6

Design Parameters Design Goals: I ▪ Application of a singular Yaskawa Motoman GP8 II ▪ Application of a singular fluid pumping device III ▪ 240 syringes per hour or 4 syringes per minute ▪ Positioning of unboxed syringes for introduction into the automated process University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 7

Design Parameters Application of Nephron Operators: I ▪ Two operators will be expected to interact with the process by setting up the pump, II loading syringes, loading caps, and conducting calibrations as needed III ▪ One additional operator will be expected to perform quality checks of the capped syringes being dispensed from the storage container University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 8

Process Simulate Section II University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 9

Process Simulate I II III University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 10

Process Simulate: Advantages ▪ Prior to the start of production, I optimization of the assembly process II can result in a more accurate and III efficient manufacturing plan. By utilizing assembly simulation to verify all process operation steps, the team can achieve: ▪ Improved time-to-volume production ▪ Reduction in overall planning time ▪ Shortened production setup time ▪ Faster overall ramp up and delivery timeline ▪ Simulation Panel Greater control over dependent variables which decreases potential for contamination University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 11

Equipment and Components Section III University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 12

Equipment: Essential Manufacturing Materials Syringes: I ▪ 10 mL II III 503b Drugs: ▪ Multiple assortment of drug types ▪ Different properties Caps: ▪ Screw on type ▪ 270 degrees of rotation for full seal ▪ Universal across syringe sizes 10 mL syringe with cap University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 13

Equipment: Robotics Yaskawa Motoman GP8: I ▪ High speed, compact 6 axis robot II ▪ 727 mm horizontal reach III ▪ Small mounting footprint ▪ User friendly interface/programming ▪ Jog to teach capabilities Yaskawa GP8 University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 14

Equipment: Gripper OnRobot RG2 Collaborative Gripper: I ▪ Adjustable gripping stroke from 0 mm to 110 II mm (4.3 inches) III ▪ Adjustable gripping force from 3 N to 40 N ▪ Infinite rotation – cable connection turns with gripper ▪ Out of the box compatibility with Yaskawa Robotics ▪ Fail safe, retains gripping force if power is cut ▪ Customizable Fingertips (rollers to facilitate rotation) Mounting of RG2 Source: OnRobot.com University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 15

Equipment: Gripper Schunk EGP I ▪ Electric 2-finger parallel gripper II ▪ Compact dimensions III (L= 64 mm, W= 35 mm) ▪ Designed for clean environments ▪ 10 mm Stroke per jaw ▪ Max gripping force of 300 N Schunk EGP Source: schunk.com University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 16

Equipment: Baxter 5300 Repeater Pump Pump Currently in use at Nephron: I ▪ Max flow rate 13.5 mL/sec (water) II ▪ Accuracy of +/- 1% over 2mL III ▪ Peristaltic pump ▪ Liquid remains sterile ▪ Inaccuracies overtime Actuation is currently a pneumatic and manually engaged bellow Depiction of peristaltic pump functions University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 17

Equipment: Masterflex L/S Pump System Overview: I ▪ Stainless steel peristaltic pump II ▪ Remote I/O allows real-time control III of pump speed, flow rate, dispense volume ▪ Max flow rate is 1700 mL/min ▪ Open-Head Sensor to prevent improper setup ▪ Masterflex Leak Detector will shutdown the pump in less than 1 second in the event of a leak or tubing failure (accessory) Masterflex L/S Pump Source: masterflex.com University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 18

Equipment and Components: Cap Package I II III Model Drawing of Cap Package University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 19

Equipment and Components: Cap Array I II III Model Drawing of Cap Array University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 20

Equipment and Components: Syringe Dispenser ▪ We have begun to experiment with physical designs I ▪ May we have a model of the syringe dispenser we saw during our tour of the plant? II III ▪ How many syringes is an optimal number to be able to store at one time in the slide? ▪ Can the syringes roll without disrupting the integrity of the seal? University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 21

Project Phases ▪ Inception: ▪ Executive kick-off ▪ Develop automation strategy road-map to prioritize schedule ▪ Planning: ▪ Identify and document current manual process ▪ Develop and critique conceptual processes ▪ Design and build: ▪ Identify, produce, and install all hardware and controlled devices ▪ Design finalized process ▪ Testing: ▪ Perform unit testing ▪ Evaluate the automated process ▪ Deployment and commissioning: ▪ Confirm final baseline requirements and deliverables ▪ Plan for full deployment and implementation ▪ Close-out and hand-over: ▪ Develop a defect reporting procedure ▪ Submit end stage report University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 22

Goals Going Forward June: ▪ Pump selection ▪ Order needed equipment ▪ Gripper selection ▪ Decide on most suitable off the shelf solution ▪ Configure gripper for our purposes ▪ Further the depth of our Process Simulation ▪ Cap array finalization ▪ Move into permanent McNair location July: ▪ Finalize design of syringe dispenser ▪ Number of syringes per fill ▪ Most efficient dispensing angle ▪ Base design ▪ Shelf concept ▪ Fixture concept University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 23

Q&A ▪ Open discussion University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 24

The Implementation of Robotic Automation for Syringe Filling Processes John Cutler, Perry Diamond, Wyatt Jones, Jorden Krueger, Jackson Payne Dr. Noble Anumbe, Dr. Ramy Harik, Jay Henderson, Kaishu Xia University of South Carolina May 31, 2019 University of South Carolina Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne 25