In today’s global medtech manufacturing landscape, competition is relentless, customer expectations are rising, and margins are tighter than ever. In this transformative age, artificial intelligence (AI), engineering innovation, manufacturing excellence, and automation aren’t just buzzwords; they are the backbone of sustained growth and operational agility.

The capabilities of advanced robotics, AI, smart data systems, and lean thinking are opening new doors—streamlining processes while empowering people to amplify their impact and build resilient, scalable systems that outperform yesterday’s limits.

Robotics & Automation: The Productivity Game-Changer

Imagine a facility where robotic arms tirelessly execute repetitive, high-precision tasks with 99.9% accuracy, 24/7. This isn’t tomorrow; it’s happening now. With the integration of robotics into production lines, companies are achieving unprecedented uptime, improving product quality, and redeploying skilled labor into higher-value roles.

While the term automation brings to mind speed and efficiency, it offers much more. Automation means consistency, safety, scalability, reduced scrap, and improved workplace ergonomics. In some cases, cycle times can be reduced by up to 35%. Just as importantly, automation can lead to a meaningful reduction of ergonomic injuries and process rework/scrap rates.

Case in Point #1

One automation project is saving millions and reshaping operations for a company. At TEAM Technologies’ North American facilities, an investment in automation is delivering significant returns, both in performance and profitability. The initiative targets the full automation of a previously labor-intensive assembly process for a high-volume, Class II medical device. The results have been transformational (Table 1). 

This represents a 180% increase in throughput with a 93% reduction in labor. Beyond productivity, the company gained in process reliability, product consistency, and overall quality assurance, all of which equated to significant savings. 

Strategic Gains and Long-Term Value

• Cost Savings: With fewer labor hours and increased throughput, the cost-per-unit dropped significantly.
• Price Stability: A three-year price hold was secured with the customer—extending a two-year freeze—reinforcing long-term cost control.
• Investment Security: The company and customer worked collaboratively to develop an arrangement that ensured consistent demand throughout the payback period and beyond. This collaborative approach helped to justify the capital investment and reduce risk. 

Why It Matters

In a global environment where cost, quality, and speed must be carefully balanced, this project illustrates how intelligent automation can deliver all three. It’s not just about accomplishing more with less; it’s about doing it better, faster, and smarter.

By eliminating unnecessary manual processes, standardizing output, and aligning commercial agreements with operational performance, the location has become a benchmark for scalable, sustainable manufacturing.

AI-Powered Systems: Transforming Quality Control

The integration of AI in quality inspection is changing how the industry can ensure consistency in the process. AI systems can quickly analyze data, detect defects, and predict equipment failures, leading to better quality, higher efficiency, and less waste. For service provider customers, this results in lower costs and more flexible operations.

Case in Point #2

To enhance quality control on many manufacturing lines across the company, vision systems equipped with AI-based inspection tools are being incorporated. The system uses deep learning to identify subtle defects and variations that traditional rule-based methods often miss, particularly on complex surfaces. By automating tasks like scratch detection, character recognition, and part verification, the AI-driven camera significantly reduced false rejects and inspection time. It also minimized manual setup by automatically optimizing lighting, focus, and inspection parameters, allowing the company to deploy quickly and adapt to changes in production with minimal operator input. This upgrade led to improved consistency, faster line throughput, and a more robust quality assurance process.

Data Analytics: Turning Information into Action

Where decisions were once based on yesterday’s reports, real-time analytics now provide a live view of a company’s operations—from overall equipment effectiveness trends and downtime reasons to scrap rates and bottlenecks. 

By leveraging machine-level sensors, Internet of Things (i.e., connected) devices, and advanced analytics platforms, a company can shift from reactive decision-making to predictive. The power of data lies not just in its collection but in how it drives informed action.

Lean Manufacturing: The Foundation of Excellence

Lean isn’t a project, it’s a mindset—one rooted in continuous improvement, respect for people, and the relentless elimination of waste. Through Kaizen events, value stream mapping, and frontline engagement, changeover times can be reduced and non-value-added activities eliminated on the production floor and beyond.

Case in Point #3

At a U.S.-based site, margins on a production line running for less than a year needed to be improved. The manufacturing excellence team applied the Theory of Constraints to identify and address key bottlenecks while systematically eliminating waste across the process. These targeted efforts delivered a 34% increase in throughput and cut labor in half, resulting in direct savings of $408,000. More importantly, the initiative created a cultural shift from operator training and labor dependency to long-term process stability and continuous improvement.

Smart Manufacturing: The Connected Enterprise

The era of siloed departments and disconnected systems is over. Smart manufacturing links machines, people, and data into one cohesive ecosystem. From automated quality alerts to digital work instructions, factories that think, learn, and evolve are being developed and constructed.

This digital infrastructure supports faster decision-making, fewer manual errors, and better cross-functional collaboration. It’s not about being high-tech for the sake of it; it’s about enabling agility in a world that demands speed.

Cost Reduction & Inventory Optimization

Many associate cost savings with headcount reductions, but real savings often originate from smarter inventory management, tighter vendor collaboration, and operational efficiency. By deploying automated inventory systems and demand-driven replenishment, raw material stockouts and carrying costs can be reduced across critical supply chains, providing significant financial gains.

Businesses can thrive from having live visibility into inventory levels, material consumption, and supplier lead times—empowering purchasing teams to make smarter and faster procurement decisions.

Conclusion: Excellence is Engineered

Manufacturing excellence isn’t a destination—it’s a discipline. It’s the fusion of engineering innovation, digital intelligence, and operational rigor. By investing in automation, embracing data-driven decision-making, and building smart, lean operations, companies won’t just keep pace, they’ll set the pace. The future of manufacturing will be won by those who can deliver precision at scale, adapt to disruption, and continuously improve.

Check out the Voices of the MPO Summit: TEAM Technologies Shares Insights on Supplier Reduction

Kyle Ragan is the director of manufacturing excellence with TEAM Technologies. With a passion and mission for automation, Ragan oversees the capital processes for equipment and facilities across TEAM Technologies. Certified as a Six Sigma Black Belt, he ensures TEAM Technologies’ operations meet safety, quality, cost control, and efficiency standards for both the company and its customers.