Case Studies

Automation Engineering Expertise

McClellan's expertise in automation engineering and machine manufacturing spans across various industries including medical devices and diagnostics.  We have been successfully designing and engineering complex custom automation systems since 1989.  Please read about how we have solved some of our clients' automation challenges.

For more information on McClellan's custom automation engineering solutions, please contact us.

Portable Sub-Assembly Station

The Customer needed to improve assembly quality because of high production demands. They required an automated system to assemble a three component sub-assembly. Their current process was using hand fixtures. A Silicone Gland, Center Post, and Inlet Housing were assembled, a 1000 cps silicone oil was applied to the silicone gland (approx. 5 microliters), and offloaded into bulk.

Fully Automatic Equipment with Rapid Changeover

Upon the success of the sub-assembly machine and the increasing demand for the customers product, McClellan was requested to design and build a fully automated assembly machine for their medical IV Valve. This involved assembling four components in two configurations.

Disposable Panel Assembly System

The client needed machines designed for these projects; the prototype on the McClellan floor, (2) pallet indexers (1) 16 feet, (1) 10 feet, (1) Singles Panel Assembly Machine, (1) GHP/PAP Assembly Machine.

Industrial Consumable Assembly Machine

Customer desired to significantly improve on production rates from existing machine, as well as increased uptime, higher part quality, and automatic packaging. All goals were realized with one machine.

Web-based Assembly Machine

Customer desired to be first to market with assay production of this kind. Finished product from the McClellan machine had to meet or exceed calibration samples made in the laboratory-- this was realized with frequent analysis during debug & acceptance runs at our facility.

Fill and Assembly Machine

The Customer needed a machine to automatically fill and assemble their Dispenser product. There were over 100 different reagents used, with multiple change-overs each day. There were multiple volumes to be dispensed ranging from approximately 7 ml to approximately 30 ml. The goal for this machine was to automatically wash, fill, prime, cap, label, and add shipping key and nozzle cap to the client’s dispenser.

IVD Assembly Machine

The Customer needed a Serological Device Assembly Machine. Their existing equipment was 13 years old and not meeting their current capacity requirements. The goal of the machine was to: • Design and build a machine using their existing machine design concept. • Design improvements into several areas. • Have a machine rate approximately 200% of their existing equipment. • Incorporate a vision system to inspect 80% of the device. Remaining inspection to be handled by incoming inspection. Their existing equipment required operators to perform 100% inspection (up to 6 operators required for the inspection process). • Accommodate (5) card configurations with minimal effort required to change-over product.