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those hand tools and other instruments.


The company develops


products for many areas of minimally invasive surgery from gynecology and gen- eral surgery to products for shoulder, knee and hip. For example, surgeons will use ConMed’s instruments to implant anchors and suture assemblies for stitching torn ACL ligaments in place for them to heal. Some surgical devices and instru- ments can involve as many as 60 individual compo- nents or as few as three. Aluminum makes up


ConMed makes suture anchor tips from materials that include titanium, PEEK plastic, and even a poly lactate acid material the body absorbs after a certain amount of time.


about 40% of the parts the shop machines, stainless steel another 40% and brass and titanium the remaining parts. And for its implantable anchors, ConMed makes them from materials that include a poly lactate acid material the body absorbs after a certain amount of time, PEEK plastic and special grades of titanium. All products are manufactured utilizing LeanSigma methodologies, and ConMed preci- sion machining typically holds machined part tolerances of ±0.0005" (0.0127 mm).


Inside a Production Cell ConMed runs its most recent Mazak production fl ow cell in two-shift operations. Parts enter the cell as raw material, go from the Mazak Integrex 200SY multitasking machine to the three-axis VCN 410A, then to EDM and honing ma- chines if needed, and fi nally to secondary operations such as tumbling surface fi nishing, washing and anodizing. All gaging, measuring and inspection are also done within the cell.


The cell processes a variety of parts, all of which are alu- minum. On average, about nine different jobs run through the cell, and job changeovers typically can occur multiple times within the same day to every three or four days depending on the business needs. According to Mike McCool, senior manufacturing engineer at ConMed, production fl ow cells let them divide part pro- cessing among multiple machines that perform the various required machining operations simultaneously. This, he said, makes for faster throughput, and multitasking machines con-


tribute further to that output by providing shorter overall part-machining cycle times. Companywide, ConMed employs a total of 3600 people, and 1100 of those work at the Largo facility. The company used to have a single factory and one plant manager but now has nine of what it calls focused factories at the Largo location. Largo precision machining has 18 Mazaks currently in use in its cellular manufacturing ar- rangement. “We really benefi t from the Mazak controls,” said Kalo. “With both new and


many vintages of Mazaks in our facility, the common control platform is such that our machinists can move from one machine to the next and seamlessly run each of them. Our operators are not dedicated to one piece of equipment, so the control commonality helps us very much in cross training our people.” According to Kalo, ConMed’s machining needs differ from those of the average job shop. Part processes must be highly capable and repeatable. The company’s Mazaks, he said, are very precise and provide critically needed performance consistency.


“High effi ciency and short developmental lead times will continue to drive our success.”


“High effi ciency and short developmental lead times will continue to drive our success,” added Mazurek. “For the future, we will work toward producing component iterations even faster and getting new products to market even quicker. We need to manufacture today what sold yesterday, and machine tool technology from Mazak gives us the speed and fl exibility to do so.”


Edited by Yearbook Editor Michael Anderson from information provided by Mazak.


75 — Medical Manufacturing 2015


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