Leak Testing for Cellular Manufacturing

Leak Testing for Cellular Manufacturing

Cellular manufacturing is a lean manufacturing model. The goal of cell manufacturing is to save time and space on the assembly floor by grouping machines together by the specific task they accomplish. These grouped machines, or “cells” are then lined up in the form of an assembly line. The Zaxis PD has been specifically designed to fit in a manufacturing cell.

Lean manufacturing is a methodology developed by Toyota and defined by James Womack and Daniel T. Jones in 1996 in their book Lean Thinking: Banish Waste and Create Wealth in Your Corporation. Womack and Jones define lean manufacturing as any system that follows the following standards; “Precisely specify value by specific product, identify the value stream for each product, make value flow without interruptions, let customer pull value from the producer, and pursue perfection.” (Lean Thinking p10)

Using the lean methodology, the concept of cell manufacturing was created to streamline assembly line flow. As seen in figure 8-4 from The Toyota Way, a common cellular manufacturing format is a U-shape which promotes good communication between workers. In a fully automated assembly line, the U-shape can make monitoring the entire line easy.

When integrating a leak tester into a cell-based manufacturing format, the most common issues are size and information displays. Large testers take up valuable space and often need to be moved away from the line and connected to products via long hoses. This adds excessive volume to the leak test effecting test accuracy. Some smaller testers can be placed right on the assembly line as close to the products as possible but many of these testers have had their displays removed to save space.

This figure from The Toyota Way shows the design of a U-shaped cell, graphing the paths of two employees through it. (https://commons.wikimedia.org/wiki/File:Figure_8-4_from_The_Toyota_Way.png)

The Zaxis PD was designed to be perfectly integrated into manufacturing cells. With the size of a 6” cube, the Zaxis PD is compact enough to fit right on the assembly line close to the product. This consolidates the UTT (Unite Under Test) keeping test accuracy high. In spite of the small size a clear LCD color touchscreen is integrated directly into the Zaxis PD. The integrated touchscreen enables at-a-glance leak test monitoring on the production floor.

Every detail of the Zaxis PD was fashioned for ease of use in a cell manufacturing environment.

  • Wall mounting plates for easy instillation
  • Integrated leak standard port and with dedicated valve
  • Onboard processing
  • USB port for simple data collection
  • Automatic pressure control that allows multiple tests to run at varying pressures
  • Bottom mounted connectors to minimize internal test volume and simplify connectivity

 

Visit our downloads page for more information and to download the Zaxis PD data sheet.

Click here to request a quote or call us at +1-801-264-1000.  

Leak Testing Sealed Components – Live Discussion

Leak Testing Sealed Components – Live Discussion

Leak Testing Sealed Components – Live Discussion

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The Ideal Gas Law & Leak Testing Video

During leak testing, changes in pressure can occur due to changes in temperature, volume, and number of moles of the gas.

Ideal Gas Law & Its Effects on Leak Testing

Pressure, volume, moles, and temperature During leak testing, changes in pressure in the test part are of primary interest. When a test part is filled with air (or any other gas), it initially expands inside the part to occupy its volume. When the part finally reaches...

Configure a Leak Tester

Contact us today to find the right solution for your needs.
Leak Testing in Manufacturing – Live Discussion

Leak Testing in Manufacturing – Live Discussion

Leak Testing in Manufacturing – Live Discussion

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The modular design of Zaxis leak testers enables us to meet the demands of a wide variety of applications.

Neuma Four Channel Leak Test Solution

Neuma LLC. is a production design firm that specialized in Medical Engineering, Packaging, Testing, Electrical Engineering and Sterilization. The engineers at Neuma like to "transform technologies into medical solutions." It is with this approach that they integrated...

Covid 19 Response Thank You from Air Logic

In response to Covid 19 many companies had to react and adapt quickly. Air Logic sent our employees this wonderful thank you video.

The Ideal Gas Law & Leak Testing Video

During leak testing, changes in pressure can occur due to changes in temperature, volume, and number of moles of the gas.

Ideal Gas Law & Its Effects on Leak Testing

Pressure, volume, moles, and temperature During leak testing, changes in pressure in the test part are of primary interest. When a test part is filled with air (or any other gas), it initially expands inside the part to occupy its volume. When the part finally reaches...

Configure a Leak Tester

Contact us today to find the right solution for your needs.
Dispensing Buffers for Covid Testing

Dispensing Buffers for Covid Testing

Dispensing Buffers For Covid Testing

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If you guys are in that stage of making some sort of vials that you’re filling testing kits for reagents, or whatever the case may be, we have a solution to help you fill your vials quick and very accurately, and keep your production rate as fast as possible.

Metered Dispensing

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Dispensing Buffers For Covid Testing, Video Transcript

Hello. Welcome to the Zaxis video blog. Today we’re going to talk about filling up vials for Covid testing kits. We’ve had a lot of customers who were either already making some sort of kit or now are making some sort of Covid testing kit, so we’re getting a lot of pump applications for this. The majority are running somewhere between 1 and 3 ml shots. To represent, basically what the vials look like [I have] this little syringe. But somewhere between 1 to 3 ml is typically the dispense [volume] of the buffer solution that is carrying the dna, saliva, whatever they’re using for the kit.

With our pumps, you have a 1% or better accuracy with less than half a percent repeatability after that. So when you’re pumping a real expensive fluid, like those buffers tend to be, the accuracy is very important. Not only can you do it accurate[ly] but you can do it very fast. A lot of our customers are currently shooting, i’ll use this as a vial, they’re filling up a small vial to go in the kits. Right now you may be doing one every seven/eight seconds, whatever the case may be. As your production grows and you can find ways to speed that up.

We can hold that same accuracy with our pumps, to go up to maybe doing one a second one every two seconds. We’re doing quite a few 8-up projects right now where we are filling multiple vials at a time as they’re coming down the assembly line. Some have a real small end you’re shooting into. Some have a larger funnel type. That’s all going to play with different nozzles and tubing that we’ll use in order to shoot it in and not make a mess.

If you guys are in that stage of making some sort of vials that you’re filling testing kits for reagents, or whatever the case may be, we have a solution to help you fill your vials quick and very accurately, and keep your production rate as fast as possible.

Thanks for tuning in and we’ll come at you next week with another video from Zaxis.

ISO 10555 Correlation to a Pressure Decay Test

ISO 10555 Correlation to a Pressure Decay Test

ISO 10555 Correlation to a Pressure Decay Test

Air to Liquid Correlation

Often a process or product has an ISO or similar standard for leak testing.  The following describes how a customer took the ISO 10555 leak test and correlated it to a pressure decay leak test using an Isaac HD pressure decay test.

The ISO 10555 process states that a product can leak no more than one falling drop of water in less than 30 seconds when pressurized to 3 ATM of liquid pressure.  The following describes the tests that were performed to correlate this to a nondestructive pressure decay test.

A group of parts were gathered that had been determined to be leak free.  Some of the parts were sent out to a company to have holes drilled through them in varying diameters.  The part was a catheter and the hole was drilled through the catheter hub directly into the eventual fluid path of the catheter.  The holes varied in size from 1 to 20 micron in diameter.  The parts were then taken and tested with air.  The customer wanted to use 15 PSI of air pressure as their test medium.  The laser drilled catheters were first put on a flow meter to determine the amount of flow through the hole.  Once a flow had been recorded the parts were put on an Isaac HD pressure decay tester to measure the amount of decay that they generated.  The pressure decay test was repeated four times with a one minute interval between tests.  Once this data had been recorded the parts were tested with water.  The parts were pressurized with water to 3 ATM and monitored for water drops forming.  Each part was timed and the timer stopped once the drop formed and fell off of the part.  The following chart shows the air flow, diameter and time for the drop to fall.  The study determined that for a drop to fall the hole size had to be 10 micron and the air flow at 15 PSI was greater than 2 SCCM.  A leak standard of 2 SCCM at 15 PSI was then created to be used for test development.

Configure a Leak Tester

Contact us today to find the right solution for your needs.

Issac HD

The Isaac HD packs industry-leading capabilities into a small package. Isaac HD is an out of the box solution for your leak testing needs.

Covid 19 Response Thank You from Air Logic

In response to Covid 19 many companies had to react and adapt quickly. Air Logic sent our employees this wonderful thank you video.

The Ideal Gas Law & Leak Testing Video

During leak testing, changes in pressure can occur due to changes in temperature, volume, and number of moles of the gas.

Leak Testing Sealed Components – Live Discussion

Leak Testing Sealed Components - Live DiscussionSpecially designed for chamber tests, the Zaxis drawer fixtures come in a variety of sizes to fit your application.Contact us today to find the right solution for your needs.

Dispensing Buffers for Covid Testing

If you guys are in that stage of making some sort of vials that you’re filling testing kits for reagents, or whatever the case may be, we have a solution to help you fill your vials quick and very accurately, and keep your production rate as fast as possible.

Configure a Leak Tester

Contact us today to find the right solution for your needs.