Zero-Defect Delivery on 40,000 Medical Device Housings
A diagnostics equipment manufacturer required a full production run of STS housings with zero cosmetic or dimensional defects at the point of delivery.
The challenge
A diagnostics equipment manufacturer needed 40,000 injection-moulded housings delivered across four months, with zero tolerance for cosmetic surface defects or dimensional variation outside a tight datum-referenced tolerance band.
What we did
We ran 100% visual inspection under controlled lighting alongside statistical dimensional sampling on every shift, with any mould-side variation flagged and corrected before it reached a full production lot rather than after.
40,000
Units delivered
0
Field-reported defects
4 months
Full program duration
The zero-defect result held across the full run, and the inspection protocol built for this program is now standard practice for medical-grade components across our injection moulding line.
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