Tray Pack Neuro Line Capacity Optimization

Abstract

This study focuses on optimizing the capacity of the Tray Pack Neuro packaging line at Boston Scientific’s Dorado, Puerto Rico facility, in response to rising demand for neuromodulation devices. The project addressed key operational challenges, including high labor costs, limited space utilization, and constrained throughput, all within the strict regulatory framework of medical device manufacturing. The primary objective was to enhance process efficiency and resource allocation without compromising compliance or quality. To achieve this, the DMAIC methodology (Define, Measure, Analyze, Improve, Control) was employed, enabling a structured analysis of current operations. Time studies and statistical tools were used to measure performance, supported by Voice of the Customer (VOC), Critical to Quality (CTQ) parameters, and Lean manufacturing principles to guide data-driven improvements. Findings revealed inefficiencies such as overstaffing, bottlenecks, and process variability—particularly at the Issue Components and Load Tray stations. Targeted interventions included the installation of Optical Character Recognition (OCR) systems, a redesigned layout to optimize space, and a sampling-based verification plan to streamline quality checks. As a result, the project achieved an estimated annual labor cost reduction of $115,797, a 57.8% decrease in space usage, and a 37.1% increase in line capacity. In conclusion, the Tray Pack Neuro line is now better equipped to meet a projected 8% demand growth by 2026. The optimization not only improves current operations but also lays the groundwork for sustainable, scalable performance through standardization, automation, and a culture of continuous improvement in a high-demand, highly regulated environment.