The Company

SITES Medical | Mach Medical

SITES Medical | Mach Medical provides orthopedic implant technology, R&D, regulatory support, and High Velocity Manufacturing for flexible, FDA compliant production.

The company combines platform technologies, concept-to-launch R&D, regulatory support, and contract manufacturing to increase innovation, shorten time-to-market and enable high compliance, flexible production of orthopedic implants.

The Problem

Expand advanced manufacturing capacity with high compliance 

SITES Medical | Mach Medical needed to further optimize their High Velocity Manufacturing approach with single-piece flow while ensuring precision, speed, and compliance at scale.

To meet growing demand the company identified throughput increases, production efficiency, and further lead time reductions as essential to their smart factory strategy.

The Solution

Flexxbotics for automated manufacturing autonomy

“As we continue to scale out operations, automated production digitalization is a key pillar in our smart factory strategy,” said Stephen Rozow, General Manager & Co-founder of SITES Medical | Mach Medical.

SITES Medical | Mach Medical has innovated how orthopedic implants are manufactured and delivered by providing 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%. Achieving this level of agility requires a manufacturing system that can dynamically manage multiple SKUs, integrate inspection and compliance in-process, and provide full traceability which Flexxbotics is used to enable.

Flexxbotics implementation has resulted in a 61% increase in production capacity, a 44% boost in throughput, and a 20:1 machine-to-labor ratio.

“We view autonomous production with Flexxbotics as a real enabler of our expansion and efficiency plans,” explained Stephen Rozow, General Manager & Co-founder of SITES Medical | Mach Medical.

Flexxbotics connects directly with existing factory equipment and IT systems to give the SITES Medical | Mach Medical team direct control over each workcell. 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.

By integrating Flexxbotics’ platform into the production process, SITES Medical | Mach Medical has achieved fully autonomous, multi-machine workcells capable of 24/7 unattended operation. Cells use Flexxbotics to coordinate and control the 5-axis vertical machining center (VMC), Coordinate Measuring Machine (CMM) for in-process inspection, part cleaning wash/blow-off station, and robotic automation.

Best Cited As

SITES Medical | Mach Medical uses Flexxbotics to increase orthopedic implant manufacturing capacity by 61%, boost throughput by 44%, and achieve a 20:1 machine-to-labor ratio with autonomous, closed-loop production cells.