Problem
Cupping pads and leech pads were still being prepared one at a time by hand. Opening the tray, placing the pad, gluing it and cutting it were independent steps that created errors.
Solution
I ran all the steps through a single line. Raw material is fed in, formed with heat, the pad is applied with a dispenser, the tray is transferred and the product is cut in the final format. Every piece comes out at the same size.
Lessons learned
The relationship between adhesive viscosity and dispenser pressure was the most critical parameter across different product groups. Calibrating this relationship took longer than designing the mechanism.
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