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Rapid scaling through medical assembly

How Zettl set up a complete pre-assembly line within two weeks and enabled a medical technology manufacturer to produce high volumes

A person wearing gray gloves uses tweezers to assemble small metal parts and gears on a workbench.

Initial situation

A medical technology manufacturer required precisely pre-assembled assemblies for a new product portfolio. The components were sensitive, functionally critical and required the highest assembly quality. However, the manufacturer was unable to expand capacity internally.

The challenge

Short project times, complex mechanisms and high volume requirements made a fast, scalable solution necessary. In addition, tight tolerances and an error-free functional sequence of the assembled mechanisms were crucial.

Solution

Within two weeks, we set up a complete pre-assembly line and provided a team of 80 qualified employees. We took over the incoming goods inspection, mechanical pre-assembly, fine-tuning of the functional mechanics and a complete testing and documentation chain.

Result

The manufacturer was able to achieve high quantities at short notice, secure its ability to deliver and expand production without having to increase its internal workforce. The ready-to-install assemblies were integrated directly into the end product without reworking.

Conclusion

High quantities despite short lead time

Stable production processes without internal capacity expansion

34 % lower costs thanks to outsourced pre-assembly line

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