Boston, MA – Flexxbotics, delivering digital solutions for robot-driven manufacturing at scale, has announced that Mach Medical, a medical device contract manufacturer, has deployed Flexxbotics for advanced robotic machine tending with autonomous process control. Using Flexxbotics enables Mach Medical to further optimize the High Velocity Single-Piece Flow Manufacturing approach – delivering precision, speed, and compliance at scale.
By integrating Flexxbotics’ platform into the production process, Mach Medical has achieved a fully autonomous, multi-machine workcell capable of 24/7 ‘lights-out’ operation. The cell includes 5-axis vertical milling operations, a Coordinate Measuring Machine (CMM) for in-line inspection, and a custom part wash/blow-off station – all orchestrated by a single robot using Flexxbotics technology.
The automation cell implementation has already resulted in a 61% increase in production capacity, a 44% boost in throughput, and a 20:1 machine-to-labor ratio—delivering high-quality joint replacement implants with precision and consistency.
Stephen Rozow, General Manager & Co-founder of Mach Medical, said, “As we continue to scale out operations, robotic digitalization is a key pillar in our smart factory strategy. We view advanced robotic machine tending with Flexxbotics as a real enabler of our expansion and efficiency plans.”
By providing implants with a 3-week lead time and flexible lot sizes as low as one unit, Mach Medical helps orthopedic OEMs reduce inventory by up to 83% – with inventories costing OEMs an amount equivalent to 8% of sales or more, the savings start rivaling the OEMs R&D budgets. Achieving this level of agility requires a manufacturing system that can dynamically manage multiple SKUs, integrate inspection and compliance in-line, and provide full traceability – all of which Flexxbotics enables.
The Flexxbotics solution gives the Mach Medical robots full command and control over the workcell, connecting directly with all equipment and systems. Closed-loop feedback from CMM inspection results is automatically routed to CNC machines in real-time, allowing continuous, autonomous operation with full FDA compliance, including Device History File (DHF) traceability for each implant.
Tyler Bouchard, CEO & Co-Founder of Flexxbotics, said, “We are proud to partner with Mach Medical to help them enhance their High Velocity Manufacturing capabilities. We understand that next generation manufacturers in high-precision industries require multi-machine orchestration for multiple parts and operations. That’s why Flexxbotics enables advanced robotic machine tending to transform basic tending into robot-driven manufacturing at scale.”
