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

University of South Carolina 1 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

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 2 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

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 3 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Outline

• I. Design Parameters
• II. Simulation of Process
• III. Equipment and Components

University of South Carolina 4 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Design Parameters

Section I

University of South Carolina 5 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Design Parameters

Automation Responsibilities: Operators two and three will be fully automated. ▪ Syringe Filling ▪ Pump Actuation ▪ Syringe Capping ▪ Syringe Dispensing

I II III

University of South Carolina 6 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Design Parameters

Sterilization Parameters: ▪ Opening of syringe packaging must take place within the ISO 5 hooded environment ▪ Syringe tip must remain within the laminar flow at all times (preferably perpendicular 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

I II III

University of South Carolina 7 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Design Parameters

Design Goals: ▪ Application of a singular Yaskawa Motoman GP8 ▪ Application of a singular fluid pumping device ▪ 240 syringes per hour or 4 syringes per minute ▪ Positioning of unboxed syringes for introduction into the automated process

I II III

University of South Carolina 8 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Design Parameters

Application of Nephron Operators: ▪ Two operators will be expected to interact with the process by setting up the pump, loading syringes, loading caps, and conducting calibrations as needed ▪ One additional operator will be expected to perform quality checks of the capped syringes being dispensed from the storage container

I II III

University of South Carolina 9 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Process Simulate

Section II

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Process Simulate

I II III

University of South Carolina 11 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Process Simulate: Advantages

▪ Prior to the start of production,

• ptimization of the assembly process

can result in a more accurate and 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 ▪ Greater control over dependent variables which decreases potential for contamination

I II III Simulation Panel

University of South Carolina 12 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment and Components

Section III

University of South Carolina 13 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment: Essential Manufacturing Materials

Syringes: ▪ 10 mL 503b Drugs: ▪ Multiple assortment of drug types ▪ Different properties Caps: ▪ Screw on type ▪ 270 degrees of rotation for full seal ▪ Universal across syringe sizes

I II 10 mL syringe with cap III

University of South Carolina 14 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment: Robotics

Yaskawa Motoman GP8: ▪ High speed, compact 6 axis robot ▪ 727 mm horizontal reach ▪ Small mounting footprint ▪ User friendly interface/programming ▪ Jog to teach capabilities

I II Yaskawa GP8 III

University of South Carolina 15 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment: Gripper

OnRobot RG2 Collaborative Gripper: ▪ Adjustable gripping stroke from 0 mm to 110 mm (4.3 inches) ▪ 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)

Source: OnRobot.com

I II Mounting of RG2 III

University of South Carolina 16 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment: Gripper

Schunk EGP ▪ Electric 2-finger parallel gripper ▪ Compact dimensions (L= 64 mm, W= 35 mm) ▪ Designed for clean environments ▪ 10 mm Stroke per jaw ▪ Max gripping force of 300 N

Schunk EGP I II III

Source: schunk.com

University of South Carolina 17 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment: Baxter 5300 Repeater Pump

Pump Currently in use at Nephron:

▪ Max flow rate 13.5 mL/sec (water) ▪ Accuracy of +/- 1% over 2mL ▪ Peristaltic pump

▪

Liquid remains sterile

▪

Inaccuracies overtime

Actuation is currently a pneumatic and manually engaged bellow

I II Depiction of peristaltic pump functions III

University of South Carolina 18 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment: Masterflex L/S Pump System

Overview: ▪ Stainless steel peristaltic pump ▪ Remote I/O allows real-time control

• f 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)

I II III

Source: masterflex.com

Masterflex L/S Pump

University of South Carolina 19 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment and Components: Cap Package

I II III Model Drawing of Cap Package

University of South Carolina 20 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment and Components: Cap Array

I II III Model Drawing of Cap Array

University of South Carolina 21 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Equipment and Components: Syringe Dispenser

▪ We have begun to experiment with physical designs ▪ May we have a model of the syringe dispenser we saw during our tour of the plant? ▪ 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?

I II III

University of South Carolina 22 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

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 23 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

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 24 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

Q&A

▪ Open discussion

University of South Carolina 25 Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne

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