The executive team at VitalTech approached us about the manufacturing, assembly, testing, and distribution of their inaugural product: a monitored medical alert wristband.
During the initial evaluation, we looked at the functional requirements—which included a failure analysis and testing for water resistance. We also calculated the cost-of-goods-sold (COGS) and assembly time needed for volume production.
Recognizing their product and their investment were in jeopardy, VitalTech leadership authorized a complete redesign of the VitalBand prototype.
Optimizing DFMA helped us set a realistic assembly line goal of 500 units in an 8.0-hour shift—using minimal resources. The mechanical design team divided assembly into multiple subassemblies: the housing, a testable/programmable electronics assembly, an integration operation, a final test, and a laser serialization procedure.
To ensure the housing met the required IP67 rating for water ingress, we specified a UV-curable adhesive to seal the contact pins protruding from the case. For the initial prototypes, we used a handheld adhesive dispenser to apply the sealant. We realized, however, that the potential for operator error was high.
We found another opportunity to reduce overall assembly time by focusing on the electronics subassembly. The design called for a main electronic board, two separate boards for additional functions, and an antenna oriented at 90 degrees from the main board.
The challenge: How can we connect four PCBs at right angles to each other? Soldering would be time-consuming and inconsistent. Mechanical interconnects would be costly, and would take up precious space inside the housing.
The modular electronics assembly meant that we could program or reprogram the firmware as needed—and then complete the initial testing before moving to the next operation.
Anne likes things neat and tidy. As an avid gardener, she knows a pristine landscape doesn’t happen by chance—there’s always someone pruning, watering, and tending to the details. Anne is that person for IDM. “I shape things,” she says, “often behind the scenes, to make sure we deliver what we promise.”
At IDM, Anne works to “make excellence a habit” by overseeing our ISO certification program. She also helps cultivate a culture focused on customer satisfaction—whether that “customer” is internal or external. With her self-described “relentless smile” and what Frank Lloyd Wright calls “an unremitting devotion to the things you want to see happen,” Anne keeps us alert, on our toes, and bringing our very best each day. “I love working with bright people who are passionate about what they do,” she says.
When she’s not digging in the dirt, you might find Anne nurturing her love of reading at the local library.